Re: 1987 Searay sundance major hull repair advice needed.
Since we've entered the Twilight Zone, I'll offer my $.02
I think you might be able to get this done for less than you're budgeting. Skip the fiberglass entirely...you don't need it. You'll be able to get EXACTLY the same result using other materials that are far less expensive and more easily available. You'll be done far more quickly as well.
For the saw cuts / cracks, I would recommend filling with latex caulk then covering the inside and outside with duct tape. Let the caulk dry before applying the tape. You may need to buy several tubes of caulk / rolls of tape. Buy the cheapest product you can...there's no difference in the quality of materials between manufacturers. That's just a myth.
The sections cut out of the hull will be a little tougher / more expensive. You'll need a piece of drywall. Cut pieces to fit the missing sections of the hull. Don't worry too much if it's not quite right. Use the caulk to put them in place. Fill any gaps with more caulk. Once the caulk is dry, you'll need to cover the inside and the outside with a piece of garbage bag. Tape the garbage bag in place with duct tape.
Paint over everything to make it look nice. A can or two of spray paint should do the trick. Get the cheap stuff.
Do not try to mount the outboard just yet....you need to test your hull repairs. A farmer's pond would be ideal, if you can find one. A large swimming pool might also work. Until you're sure everything is okay, you should NOT put your boat in any water where other boats or people might be present. Safety first. Anyway, once you get your boat into the water, you'll need to let it sit there for a while. I would just let it sit overnight and come back to check on it the next morning.
Try to post lots of pictures so we can follow along. Video would be even better. Please, video!!
