Join Date: Aug 2008
Location: Berkeley, CA
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Filling holes in hull with epoxy barrier coat
I'm in the process of replacing all the old, corroded thru-hulls and valves (most of them gate valves) with new ones. The existing valves were bolted all the way through the hull with stainless steel, which is now corroded almost to dust.
The plan is to remove those bolts, fill in the holes in the hull, and lagbolt the new valves into new (epoxy-sealed) plywood backing plates.
I would normally clean out the holes and fill them with poly filler, then gelcoat over, but the bottom had an epoxy barrier put on a few years ago by the previous owner. Can I still use poly filler, or do I need some kind of epoxy putty? Do I need to seal that, or can I just paint over it?
(Another option that was mentioned was just to glass over the existing corroded bolts on the inside, and to leave them in the hull, but I don't like the idea of sealing a bunch of rusted metal in there.)