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Author Topic:   Fiberglass Repair on Upper Hull

clunedawgie posted 01-10-2009 08:30 PM ET (US)
My 1984 Boston Whaler Outrage has a crack in the upper portion of the hull where it meets with the gunwale. The crack is in the area above the fuel vent and continues over the laminated gunwale. I removed the rubrail and patched with THICKCEL and AEROCEL. Then glassed over with 9-ounce cloth, but the crack returned when I took [the 1984 Boston Whaler OUTRAGE] out [to sea]. Any suggestions on repair?
jimh posted 01-11-2009 08:54 AM ET (US)
Typically a crack means there was stress at that area and flexing. When you make a repair you have to stabilize the area so that there is no movement or flexing. In your case that probably means enlarging the area of the repair and making a stronger repair to the structure of the hull in that region.
macfam posted 01-11-2009 08:59 AM ET (US)
clunedawgie,
You may want to read the attached links. The crack near the fuel vent may be minor, or in some cases may be critical to hull integrity.
http://continuouswave.com/ubb/Forum1/HTML/008680.html
http://continuouswave.com/ubb/Forum3/HTML/002574.html
Tom W Clark posted 01-11-2009 11:37 AM ET (US)
That crack is a known problem with the Outrage 25 models. The factory published a repair plan and kit for reinforcing the crack. It basically involved a huge patch about nine feet long laid over the topsides spanning the cracks.
You do both sides of the hull using a special cloth and then feather it out well and re-gel coat the patch.
This is the only solution I have ever heard of for this problem.
clunedawgie posted 01-11-2009 03:11 PM ET (US)
Mahalo jimh,macfam,& Tom
Great info. I was afraid I would have to increase the size of the patch. Didn't know the extent. major surgeory. i may, with your permission Tom, email you to get a copy of the "factory remedy". Mahalo again & Aloha.
Tom W Clark posted 01-12-2009 12:18 PM ET (US)
Mark,
The copy I have is a very poor facsimile (literally a low resolution FAX). Let me see if I can come up with a better scan.
In the mean time, here is the text of the instructions (reproduced as closely as I can here):

FRACTURED TOPSIDES REPAIR
USE STEPS 1-4 ON INSIDE, OUTSIDE AND TOP OF GUNNEL:
1. Cut away fractured glass 1/2" on either side of the crack to form a 1" wide opening.
2. Taper grind original skin out 6" from the crack as shown, and dig out foam from about 1" behind glass.
3. Stuff areas behind glass and cut-out area with resin and chopped fiber mash until full.
4. Mat over area with multiple layers of 2 oz. mat until back to original thickness. After mat is cured, grind it flat and flush with original skin. Use a straightedge to check.
USE STEPS 5-7 ON EXTERIOR TOPSIDES:
5. Rough up topsides to 60" of either side of already repaired area.
6. Cover entire topsides from under gunnel to chine, with 4 layers of COFAB 10 oz. uni-axial material 96" long. Each layer should be staggered 6", and the first layer should start 57" aft of crack. Fair each end by sanding and filling with resin paste to blend with side and show no bump (See drawing next page).
NOTE: It may be necessary to put screws in hull to hang the COFAB to prevent sagging and sliding.
7. Cover entire area with one layer of 2 oz. mat 9' long; fair each end to blend with the side.
8. Finish both inside and outside repairs with gelcoat.
0598-6
clunedawgie posted 01-12-2009 11:16 PM ET (US)
mahalo Tom
Will follow directions as best as possible. Mahalo again!!
Aloha, Mark

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Author	Topic: Fiberglass Repair on Upper Hull
clunedawgie	posted 01-10-2009 08:30 PM ET (US) My 1984 Boston Whaler Outrage has a crack in the upper portion of the hull where it meets with the gunwale. The crack is in the area above the fuel vent and continues over the laminated gunwale. I removed the rubrail and patched with THICKCEL and AEROCEL. Then glassed over with 9-ounce cloth, but the crack returned when I took [the 1984 Boston Whaler OUTRAGE] out [to sea]. Any suggestions on repair?
jimh	posted 01-11-2009 08:54 AM ET (US) Typically a crack means there was stress at that area and flexing. When you make a repair you have to stabilize the area so that there is no movement or flexing. In your case that probably means enlarging the area of the repair and making a stronger repair to the structure of the hull in that region.
macfam	posted 01-11-2009 08:59 AM ET (US) clunedawgie, You may want to read the attached links. The crack near the fuel vent may be minor, or in some cases may be critical to hull integrity. http://continuouswave.com/ubb/Forum1/HTML/008680.html http://continuouswave.com/ubb/Forum3/HTML/002574.html
Tom W Clark	posted 01-11-2009 11:37 AM ET (US) That crack is a known problem with the Outrage 25 models. The factory published a repair plan and kit for reinforcing the crack. It basically involved a huge patch about nine feet long laid over the topsides spanning the cracks. You do both sides of the hull using a special cloth and then feather it out well and re-gel coat the patch. This is the only solution I have ever heard of for this problem.
clunedawgie	posted 01-11-2009 03:11 PM ET (US) Mahalo jimh,macfam,& Tom Great info. I was afraid I would have to increase the size of the patch. Didn't know the extent. major surgeory. i may, with your permission Tom, email you to get a copy of the "factory remedy". Mahalo again & Aloha.
Tom W Clark	posted 01-12-2009 12:18 PM ET (US) Mark, The copy I have is a very poor facsimile (literally a low resolution FAX). Let me see if I can come up with a better scan. In the mean time, here is the text of the instructions (reproduced as closely as I can here): FRACTURED TOPSIDES REPAIR USE STEPS 1-4 ON INSIDE, OUTSIDE AND TOP OF GUNNEL: 1. Cut away fractured glass 1/2" on either side of the crack to form a 1" wide opening. 2. Taper grind original skin out 6" from the crack as shown, and dig out foam from about 1" behind glass. 3. Stuff areas behind glass and cut-out area with resin and chopped fiber mash until full. 4. Mat over area with multiple layers of 2 oz. mat until back to original thickness. After mat is cured, grind it flat and flush with original skin. Use a straightedge to check. USE STEPS 5-7 ON EXTERIOR TOPSIDES: 5. Rough up topsides to 60" of either side of already repaired area. 6. Cover entire topsides from under gunnel to chine, with 4 layers of COFAB 10 oz. uni-axial material 96" long. Each layer should be staggered 6", and the first layer should start 57" aft of crack. Fair each end by sanding and filling with resin paste to blend with side and show no bump (See drawing next page). NOTE: It may be necessary to put screws in hull to hang the COFAB to prevent sagging and sliding. 7. Cover entire area with one layer of 2 oz. mat 9' long; fair each end to blend with the side. 8. Finish both inside and outside repairs with gelcoat. 0598-6
clunedawgie	posted 01-12-2009 11:16 PM ET (US) mahalo Tom Will follow directions as best as possible. Mahalo again!! Aloha, Mark