Repairing small drill holes in hull

[thataway]

I have to differ with Boris on use of 5200 to fill holes. 5200 is a sealant and adhesive, but not a filler. There are several reasons not to use 5200. It discolors badly, it is damaged by UV rays, but these are not the worse problems. It is not always 100% reliable with its adhesive property. I have seen failed bonds--the one place you don't want failed bonding is in the bottom of the boat--or little plugs of 5200 coming out.

As far as filling defects on the top of the boat--probably the best is to make a small plug with epoxy or polyester and then gel coat over it. That way you get a good or perfect match.

I agree 100% with Boris on the use of JB weld for metal repair. I have a van which was rusted and 6 years later the repairs are in great shape. I know of an aluminum block 6-71 which has had JB Weld to repair a water passage on the head over 20 years ago and still working well.

Marine tex is also acceptable for filling. It will also discolor and not give the high gloss polish of gel coat. It is an thickened epoxy. I use it for small amounts, for large amounts it is cheaper and you can make up a better filler by "mixing your own"--cabisol, high density filler and white pigment in epoxy.

For the very small holes, it may not be practical to under cut them. You will get a better repair if you do. I find the Dremel tool is your friend, and there are many small bits which can be used to do the undercut easily. I keep a Dremel tool on the boats.