Campion Allante 535 transom repair

[larstore]

After buying a new, more powerful outboard for my boat, i ended up finding a wet mounting hole. Was going to brace it up with some stainless steel, but ended up wanted to fix it properly. My main issue is the fact that my transom is not flat. There are all kinds of curves, so i am not really sure how to go on with this. My plan is to remove any wood and replace with Seacast

Some before pics:

 

[larstore]

No Title

My main issue is that the transom is not flat, i need to locate where the wood is before cutting. The extended flares at the top is also visible on the inside, so they are clearly just a fiberglass mold. The part below however seems to be the same thickness as the motor mount, so i guess they put a very custom shaped piece of plywood in there

 

[larstore]

No Title

I had to start somewhere, so after talking to the Seacast people, i cut the top of the transom off to investigate. For some reason, the transom top is not closed off, it is just sealed with something that will leak after a while. I just dont see why it was made like that, but thats another question.

I continued to drill a couple of 2" deep holes on each side with a spade drill bit (approx where the outboard mounting holes are), and as you can see from the pictures: on one side the wood looks quite nice, on the other not that good.
The wood is quite solid on both sides, so i am not sure if the removal is going to be as easy as some of the "rotten transom" threads ive read

 

[Woodonglass]

you can buy 18" long spade bits and extensions so you can drill out the wood but...for this boat I'd cut the gunwhales about 6" in front of the splashwell and remove it. I'd then cut the transom on the inside using a circular saw set to just shy of the thickness. Cut a grid 2" x 2" and then use a wide wood chisel to knock off the pieces. YOu only have to replace the center section. If it's curved you just use 6 pieces of 1/4 " plywood to be able to clamp it to the outer skin and maintain the curve.

 

[larstore]

for this boat I'd cut the gunwhales about 6" in front of the splashwell and remove it. .

you mean removing parts of the splashwell itself and then remove the entire inner fiberglass skin?

YOu only have to replace the center section

Really? What if the sides are wet too?

 

[Woodonglass]

Your Hull structure indicates the sides are separate structures. If they are wet and if the tow eyes are attached then you'll cut the inner skin and replace them. Here's a pic of what I'm referencing
http://forums.iboats.com/forum/boat-...-a-splash-well

 

[larstore]

The most tempting solution is to get all the old wood out and pour seacast in top of the transom. Looks doable without cutting too much fibreglass. Worst case the top of each side (inside of hull) + the already cutted transom top.. I've read alot of good things about seacast, and it just seems so easy and non destructive..

 

[Woodonglass]

Yeah but based on how your Starbucks is built you'll never get all the wood out

 

[larstore]

Yeah but based on how your Starbucks is built you'll never get all the wood out

The centre piece looks easy enough to remove from the top. If the sides are connected (and wet), i would think they can be done in a similar fashion? Removing thr top from the inside?