Lollygaggin":1azim434 said:
...how do you folks fill the oversize holes with epoxy?
First I either "paint on" neat epoxy, or sometimes inject it with a syringe, let it soak in a bit, then suck it back out. Of course the neat epoxy is not much of a challenge.
For the thickened epoxy, I have a variety of ways I use, depending on the hole. I presume you are talking about holes you want to completely fill here, then re-drill after curing.
If possible, I arrange it so I can have an air-release hole high up (this can be tiny) and the fill hole down low -- same idea as when filling the lower unit on an outboard. Epoxy goes in low, air comes out high, and the hole gets completely filled with no voids.
With "blind" holes, it gets trickier (i.e. holes with only one opening). The "worst" is something like an oversized and undercut transom hole, because you have an unvented "cave" up high in the hole and that just loves to trap air. I tackle this in a couple of different ways, situation dependent. If I have "room" in a place where it won't show later (say it's under a flange, or behind the fuel tanks or etc.), then I try to drill a small air hole somewhere (the epoxy then fills it as part of the whole filling operation).
If I can't do any of that, but am stuck with blind holes with "upper caves" -- I had this situation with the holes for attaching my trim tab planes -- then I do one of two things: Either I put a small piece of tubing in the hole up high and try to get the air to come out that way (tends to clog), or, more reliably but more messy, I have a cup standing by to catch the overflow and just pump epoxy in like mad, letting it continue to flow back out into the cup. This tends to "flush" the air out, and I then use the epoxy from the cup to reload my syringe for the next hole.
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For big holes (like a hatch), where I'm only filling in the perimeter, I use either a syringe, a "spatula" made of a cut up milk jug (can make any shape that way), or I load up a baggie and cut off one corner like a cake decorating tool and use it like a disposable/malleable syringe.
I've probably forgotten a few things, and I'm sure others have different/inventive ways too.
Sunbeam