CONTINUOUSWAVE

Q1: Is there anything that needs to be done to prevent water intrusion into the foam from the screws that are drilled into the bilge area to hold the bracket in place since there is always some water left that the pump can't get to?

Q2: If I need to drill out wider holes to fill with something to isolate the screws from the interior of the hull what sort of drill would I need to use to drill into the gelcoat/fiberglass?

Q3: are there any other common areas on an 1987 OUTRAGE 22 I should inspect and address for repair?

Background: I bought an OUTRAGE 22 notched transom at the end of the 2025 season that already has the bilge pump installed but I want to make sure to seal anything that could allow water to soak into the foam. The starboard side of the boat already seems a bit heavier than the port side at rest and I'm not sure if this has anything to do with it, but would want to take whatever precautions I can as my old outrage 18 seemed to be heavier on this side as well.

dsullivan wrote:Q1: Is there anything that needs to be done to prevent water intrusion into the foam from the screws that are drilled into the bilge area to hold the bracket in place since there is always some water left that the pump can't get to?

The screws fasteners that penetrate into the gel coat and laminate of the hull in any area where water could be present should be installed with a sealant in the hole and on the threads.

dsullivan wrote:Q2: If I need to drill out wider holes to fill with something to isolate the screws from the interior of the hull what sort of drill would I need to use to drill into the gelcoat and fiberglass?

In the specific case of retaining a sump pump in place, there may not be so much stress on the screw fasteners that you need to create your own reinforced areas. Often just bedding the screws into the hull with a sealant or perhaps even an adhesive sealant will be sufficient to hold the pump in position for normal operation.

If fastening something that will have significant force exerted onto the hull, the typical location would have embedded wood to receive the screw fastener, so only a pilot hole into the laminate would be drilled. A slightly larger diameter hole should be drilled only in the gel coat layer, large enough that the threads and shank of the screw can pass through. This is done to avoid cracking the rather brittle gel coat with the threads of the screw or its unthreaded shank.

If there is no embedded wood in the hull, and you want to make a reinforcement under the gel coat and laminate, you would create a empty area or void in the foam below the laminate, and then fill the void with epoxy resin thickened with a suitable filler. The screw fastener can then get a good purchase when threaded into the cured epoxy. You can even drill and tap the cured epoxy and use a machine screw instead of a self-tapping fastener.

A method to create a void area in the foam under the laminate is discussed at

Repair of Loose Screw Fasteners using Void in Foam and Epoxy Filler
https://continuouswave.com/forum/viewto ... 224#p18406

dsullivan wrote:Q3: are there any other common areas on an 1987 OUTRAGE 22 I should inspect and address for repair?

You should inspect any opening in the hull that holds a fastener or a drain to be sure there is no ability for water to invade the interior of the hull and get into the foam, with special attention to any opening in the hull that is below the water line in normal operation. For example, the lower engine mounting bolts on the transom are often continually submerged; these must be completely sealed against water intrusion.

Also check all drain outlets for proper sealing.