This is neat Gene,
For my iPod case wire connector, After the first piece failed, I just use good silicone caulk, and check it frequently.
The method you describe sounds much better. My experience with waterproof stuff and sea kayaking is a multiplier of the salt water environment.
Sometimes the best stuff fails before it should.

I recently found an interesting way to make inexpensive hydrophone microphones
http://blog.makezine.com/archive/2010/03/diy_hydrophone.html

I was going to ask a Hollywood soundman I know how the silicone sealing would affect frequency response, and if epoxy might be better.
I'd love to know what the whales I've been hanging with are talking about.

Will

: DRY BAG PELICAN BOX ELECTRICAL WIRE FEED THRU

: ASSEMBLING a hydrophone/recorder system required feed thrus for a
: deck mounted dry bar holding a remote control for the Marantaz
: PMD 620 housed in a Pelican box on the floor of the Solstice
: Titan’s forward hold.
: The dry bag, a yellow bar bag from Campmor
: http://www.campmor.com/outdoor/gear/Product___34409

: was holed for a ‘Nylon Bulkhead Union Tube And Hose Fitting’
: from U.S. Plastic Corporation set on nylon fender washers from
: local hardware drilled for the Union Tube. The bag was cleaned
: with CHOH then lightly scuffed with 100 grit, cleaned again with
: CHOH. Washers were coated with ‘3M Marine Sealant 4000 fast
: cure’ and the Tube Union snugged down. The fitting was allowed
: to cure. The Tube Union was cut short to nuts.

: The drybag feed thru appears durable.

: The Tube Union was cleaned with CHOH, remote wire lead thru after
: cleaning, centered with a patches of bread bag, leaving a space
: on the bag’s outside Tube Union’s ID for a wad of Permetex
: windshield silicone.

: The Pelican box was drilled then outside surface cleaned with CHOH,
: roughed with 100 grit, recleaned then coated with 3M urethane to
: accept either a Nylon Adapter Hose Barb With Lock Nut or Nylon
: Bulkhead Union Tube And Hose Fitting.
: Wire placement and silicone as preceding. Iping silicone up from
: the main wad along the wires lead out seems to complete
: waterproofing the assembly.

: Suggestions were made to altering the Pelican surface thru flaming
: the openings area but the 3M and nylon nut compression appears
: adequate.

: U.S. Plastic Corporation
: 1390 Neubrecht Rd, Lima Ohio, 45801-3196 Phone: 1-800-809-4217