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Old 08-21-2012
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Re: Hole in hull

I did about 50 of these on my boat.
From the outside, countersink the hole a little bit. Sand it smooth with 80-120 grit. Clean with lacquer thinner or acetone on a new rag. Mix up some epoxy thickened with cab-o-sil (or mix some Marine Tex) until it's a thick paste.
Fill the hole well, smashing it deep into the hole. Smear it flat, very flat, with your spreader. At this point you can leave it or sand it smoother and leave it, or you can sand and primer and paint or use gelcoat, it all depends on how good you want it to look.
If it's at or near the waterline, I sanded the repair down as deep as a layer of impregnated fiberglass cloth is thick (about 1mm for 8oz glass) out to about 3" in diameter and then I layed-up a layer of glass over the plug to be certain that it would never leak or fall out.
In reality, I spent about 5 minutes per hole but I was doing quite a few at once.

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