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post #2 of Old 02-13-2010
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After cutting out the hole with a hole saw, remove the core adjacent to the hole to a distance outward from the hole equal to the thickness of the core. Paint the resulting groove with epoxy and then fill it with epoxy thickened to the consistency of peanut butter. Duct tape the edge of the hole to prevent the thickened epoxy from sagging. Sand when the fill has cured. [remove tape first]. Finish by glassing edge of cutout with a layer of finish cloth , like 2" 10 oz. fiberglass tape. Trim excess glass. Install bedded fitting.
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