1) use a dremil bit #115 to shape the hole(see above link)
2) tape underside
3) fill hole with unthickened epoxy, via syringe
4) let sit for 5 minutes
5) remove unthickened epoxy via syringe
6) fill hole with thickened epoxy
7) let cure
8) paint with colour match paint via q-tip
Yes counter sinking the hole is good, asuming you plan on drilling the hole out. Using a counter sink bit will help to prevent the gelcoat from chipping.
Yes thicken the epoxy, straight epoxy is brittle and should be "softened up" a bit. Particularly if you ever want to sink a screw into the filled hole in the future.
A suggestion, find a hole puch just larger than the hole to be filled. Punch a hole into tape and place around hole. After filing hole with thicken epoxy, remove tape. The tape will "catch" any overflow thickened epoxy, allowing for easy cleanup.
I am a novice at this so see the link to mainesail's site, follow his advice and you can't go wrong.
02-21-2013 07:21 PM
I've been told by a local shipwright that you use smith's epoxy sealer to treat the holes before filling them. Put the a and b parts 1:1 in a syringe and fill, let it settle, then fill again until it's saturated. Then you fill with West or something similar.
02-21-2013 05:34 PM
I have a Morgan Out Island 41. There are a ton of old hardware on the deck that I want to remove. Snaps for a nonexistent dodger, unused fairleads, deck mount for long gone spinnaker boom, etc. Some holes are in a cored deck, others are in a hollow. It is my plan to spend a weekend pulling screws and filling with epoxy. I watched a fiberglass guy repair bunch of screw holes in my pedestal last year. He used a counter sink to flare the holes. I never understood why. So I have 2 questions:
1. Should I counter sink the holes as well? Or sand it smooth and fill the hole?
2. Do I use talc or some other filler to thicken up the epoxy?