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JeffA posted 08-02-2002 08:40 PM ET (US)   Profile for JeffA   Send Email to JeffA  
I now have a (4"X3")hole down to the foam in my transom; it's a long story. I don't want to attempt this without some help. As I said, the hole is down to the foam (entire 4"x 3" area). The foam has not been damaged too much. There is only a small piece of the foam missing. Therefore, I'm not sure how to fix this. I would eventually like to gel coat the area after I fill in the hole. It would be easy if I had the firm surface of the laminate to back up the repair. Could any one tell me how to make the proper repair? Please mention the products (brand name and numbers).


Tom W Clark posted 08-05-2002 10:51 AM ET (US)     Profile for Tom W Clark  Send Email to Tom W Clark     

You can do this repair yourself. There are probably several different ways to make the repair but the Boston Whaler repair instructions will describe a method like this:

Remove any loose foam and grind the edge of the fiberglass to a knife edge with a grinder. Be sure to remove any loose bits of fiberglass. Dig out the foam behind this edge to a width of about an inch. Into this void you will pack a mixture of chopped fibers and resin and thus forming a connection on the backside of the skin.

Before this is cured you then lay a couple layer of 2 oz mat over the entire repair area. After this is cured you sand the repair area flat and apply gel coat and then sand and buff to the original finish.

This is the short answer. If you would like a copy of the repair instructions email me your FAX number and I'll send them over.

This method of repair has the benefit of requiring only polyester or vinylester lay up resin and a bit of matting as well as the gel coat matched to the color of your hull.

The resin and cloth can be had just about anywhere even your local hardware store. For gel coat I would recommend Spectrum ( )

Having just spent the weekend helping a fellow FORUM member repair his damaged Montauk hull I can say this is not a difficult process but it can be time consuming. The hardest part is getting everything smooth and fair. It is also messy.

If you have damaged the foam itself you will need to procure a bit of polyurethane foam to replace what has been removed before applying the resin.

JeffA posted 08-05-2002 07:54 PM ET (US)     Profile for JeffA  Send Email to JeffA     
I did something very similar. I removed some of the damaged foam but very litte. I then grinded down the edges of the laminate to a knife edge. I then cut pieces of fiberglass just a bit bigger than the hole and basically made a surface to bond the filler too. Before I started applying filler, I injected some polyurethane foam behind the glass. It seems to be ok.

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