Bringing the fill up to the proper thickness. After this I overfilled it a bit, and then "buttered" the tube so that it would "squooge" into place with plenty of epoxy all around.

After a couple of days of curing I cut off the excess tube and rounded over the after side. Then I prepped both sides and ran a fillet around the outside of the tube. Next I'll sand it and I may trim it slightly shorter on this (splashwell) side. I'll let the fillets cure for a longer time before ultimately gelcoating things. Hmm, I'll have to add a photo of the after side too.

"Impalement patient" as the epoxy cures. I let it cure for a couple of days before trimming it.

The tube bonded in on the splashwell side. I inserted it from astern just to where I wanted it, and let it "run wild" on the outside, to be cut off later. This made it easier to work with than a just-right-sized tube.

Bringing the fill up to the proper thickness. After this I overfilled it a bit, and then "buttered" the tube so that it would "squooge" into place with plenty of epoxy all around.

Filling the hole. First I used a dental pick and a Dremel tool to remove the core for a good 1/2" beyond the drain hole. Then I enlarged the hole in preparation for inserting a 1" ID (1-1/8" OD) fiberglass tube. Then final sanding and cleaning, and I put a good coat of neat epoxy all around the hole. After that (and will the tube prepped), I slowly built up the hole with thickened epoxy (colloidial silica). I had to do it in layers so it would not get to hot as it kicked (but all in the span of a few hours so it was still plenty green for a chemical bond).

Transom side of empty hole. What you are seeing is the balsa core of the transom, followed by the forward fiberglass skin of the transom, and then the (white) filler that fills the gap between the splashwell molding and the forward transom skin.

Drain hole after tube removed. Dry (balsa) core, thankfully, although there was only the bare minimum of sealant and no isolation of the core.

S

Bringing the fill up to the proper thickness. After this I overfilled it a bit, and then "buttered" the tube so that it would "squooge" into place with plenty of epoxy all around.

Sunbeam
Jan 13, 2013

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