Best way to fill these large openings. - SailNet Community

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  #1  
Old 01-02-2010
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Best way to fill these large openings.

Well,
I've decided to bite the bullet with regards to the white areas on my boat and paint them, this means that I can fill some of the holes that the previous owner had cut (not very accurately) for various purposes.

This first hole had some perspex screwed onto in order to provide light for the quarter berth, there is another one on the opposite side of the cockpit that's just far enough from symmetry with this one that you notice it. :P


This second hole was cut at the front of the cockpit for a bilge pump, a silly place to put it IMO and I want to fill it as well.


As you can see the thickness of laminate for the cockpit is very thin (6mm), structurally this isn't an issue I intend to but in some reinforcing beams below, however I'm at a loss for the best technique to fill the cut outs which are far far bigger than the laminate thickness.
(N.B. West system epoxy is my preferred material of choice for this job)

Any advice much appreciated.
Thanks
Rich
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Old 01-02-2010
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I would laminate a panel out of fiberglass on a piece of waxed paper on a workbench. Then cut it to fit the opening and glass it in place.
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Old 01-02-2010
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You may look at Tim's projects, I learned a lot by looking at the pics he posts, and he frequently closes ports or various openings....
here:
Northern Yacht Restoration | Tim Lackey:* One Man, One Boat at a Time

n.b. I have no interests in NYR
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Old 01-03-2010
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another suggestion

Quote:
Originally Posted by xsboats View Post
I would laminate a panel out of fiberglass on a piece of waxed paper on a workbench. Then cut it to fit the opening and glass it in place.
I would laminate a panel on the workbench as suggested, then cut it to size to just fit the hole, then laminate it to a slightly larger piece, insert the assemble from behind, epoxy it in place from the rear, then fill the remaining cracks and gelcoat from the front...
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Old 01-03-2010
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Thanks people,
I was just after some additional oppinions because there's not much thickness of material to bond to, but the structural integrity of my cockpit is fairly important!
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Old 01-03-2010
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Double it up, use a bigger backing. I would glass both sides of a piece of pywood for the parts.
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Old 01-03-2010
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If you do not want to grind, glass and paint, You could fab a Starboad panel to fit. I used 1/2 starboard to fab a new engine panel assembly for the cockpit, counter sunk the edges so it would only stick out 1/4".
I checked out your blog, a labour of love... I've restored a Santana525 which linda looks like the 1/4 tonne.
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Best way to fill these large openings.-inst_panel.jpg  
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Old 01-03-2010
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Thanks for taking the time to read my blog!
Its tempting to put the engine panel there, although I wouldn't let it stick out at all, I've seen to many snapped keys for that, especially since I have a very small cockpit so its cramped anyway.

I think I've got how I'm going to do it sorted!
Cheers
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Old 01-04-2010
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Put a layer of glass across the back; then build up from the front. When you are close to being up to the gelcoat level you can clean up any epoxy that is above the surface of the existing gelcoat; then gelcoat the epoxied-in section. The edges should be beveled back an inch or more so you will have adequate bond strength to the existing fiberglass. Use an angle grinder to bevel the edges before you start with the fiberglass/epoxy.
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