First Time Repairing Hull with Epoxy

jmb23802

Petty Officer 3rd Class
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Oct 13, 2014
Messages
79
I am planning to fill three screw holes in my transom this weekend where a transducer has been mounted. The transducer will not be remounted in this location. The boat in question is a 2003 Four Winns with a FG hull.

This will be my first time doing any hull repair or using an epoxy product. I plan to drill the holes out one step larger to ensure I have every bit of silicone out of there before I get started. Once the holes are drilled, I would appreciate any advice about process. The epoxy I will be using is the West Systems 105K fiberglass boat repair kit.

First, any prep I should do after drilling the silicone out to a clean hole (aside from blowing the dust and filings out and making sure it is dry)?

Second, should I put 1 or 2 thin coats on the internal edges of the screw holes before I fill the holes completely with epoxy? The question being of whether the core material (either wood or foam ? I haven?t got into it yet) will absorb enough epoxy to make this a process better done in two steps rather than just pumping the hole full of epoxy in one step? Also, if more than one step is best do I need to let each coat fully cure before applying more epoxy? Wait until it is tacky?

Third, the high temp on Saturday is supposed to be in the mid-50?s. Is that warm enough for the epoxy to be workable and cure properly? I know that cooler temps for epoxy slow cure time but not sure how much 50 degree temps would affect the workability and cure time.

Fourth, does the epoxy need to be completely cured before putting the applied epoxy under water when I put the boat in the lake? Not sure if I will get to the lake for another 1-2 weeks, but would be nice to know for reference. Temps are supposed to be 50?s-60?s daytime and 40?s overnight for the next week but boat is sitting in my garage so the temp swings are somewhat muted.

Finally, what is good to clean off uncured epoxy? I plan to use a syringe and possibly another tool to work the epoxy into the holes ? how do I handle tool clean up when done?

OK, I threw a lot of questions at you! Some of this is probably covered in the instructions in the West Systems kit, but any help from experienced folks would be much appreciated!
 

Woodonglass

Supreme Mariner
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Dec 29, 2009
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Epoxy likes Heat to cure. 50 degrees is borderline but you could prolly use a heat gun and or heat lamps to ensure the curing process completes. I'd recommend mixing fine sawdust with the epoxy to thicken it to the consistency of mayonaise so it will stay put in the holes. You can fill them in one go. No need to layer. Wash em out with some Acetone. Use a plastic putty knife to compress the goop into the holes and then apply some tape to cover the holes. Some halogen lights placed close to the transom for a day will prolly do the trick to get the Epoxy to kick. Anywhooo that's how I'd recommend doing it.
 

Second Chance 248

Petty Officer 2nd Class
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Dec 28, 2014
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132
I would do exactly what Woodonglass suggested. Look into West Systems Six-10, it's perfect for a small job like that and is also more user friendly for first time Epoxy use.
 

gm280

Supreme Mariner
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Jun 26, 2011
Messages
14,605
Follow Wood's suggestions and it will be great. As far as what removed uncured epoxy, either use Acetone or Lacquer Thinner. Either or will do the job. And if you are pushed for some other method, try some fingernail polish remover. It works wonders sometimes as well.
 

DeepBlue2010

Lieutenant
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Aug 19, 2010
Messages
1,305
If your objective is to just fill the mounting screws holes, why taking the epoxy route? 3M 5200' 5200 fast cure or 4200 marine sealants can do this job nicely. They are all designed to work above and below the water line.
 

JASinIL2006

Vice Admiral
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Feb 10, 2012
Messages
5,713
I patched old transducer holes in my transom with PC-11 (a marine epoxy similar to MarineTek) and it worked really well. PC-11 is pretty inexpensive and was easier to find in my area than MarineTek or West Systems stuff.
 

jmb23802

Petty Officer 3rd Class
Joined
Oct 13, 2014
Messages
79
Thanks for the advice Woodonglass and everyone else. Since I already have the West epoxy I am just going to go with it and follow the advice of Woodonglass. Sounds like 50 degrees is sub-optimal for applying epoxy so perhaps I will wait a little bit longer until the temps get warmer before I do this repair. No reason to get in a big hurry anyway.

Thanks.
 

jmb23802

Petty Officer 3rd Class
Joined
Oct 13, 2014
Messages
79
As a follow-up, I finally got around to filling the old transducer holes with epoxy and it went off without a hitch following the instructions in the West Systems kit and the advice of Woodonglass. It also helped that the temperature was in the 80's that day and after I epoxied the holes I moved the boat into the yard in direct sunlight so I could wash out the bilge - you could really smell the epoxy when it kicked off and I'm sure the sun radiating on the transom only helped the process along.

The only thing I would do differently next time is mix less epoxy. Beginner error - I mixed two packets of the epoxy from the West Systems kit because one packet did not look like enough to do the job but by the time I added enough filler to thicken up the mixture I had 10x what I needed. Not a big deal and it all turned out as good as I had hoped for.

Thanks again for the help!
 

Woodonglass

Supreme Mariner
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Dec 29, 2009
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Glad it worked out for you. You can rest easy now and be assured the boats all sealed up and ready for a season on the water!!! ENJOY!!!!:D:clap2:
 
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