How bad is this?

[Jack2048]

I am redoing the deck on my boat. I just did the one thing I didn't want to do. Cut through the hull.

I was using a cut-off wheel and misunderstood the geometery of the hull where I was trying to remove the old stringer.

The cut is about a foot long, 1/8" wide (width of cut-off wheel).

Can this be repaired ?

I was thinking something along the lines of this:

1: Tape outside
2: fill gap with epoxy / epoxy filler mix, ie: peanut butter.
3: lay over with 1708 and epoxy.

Question, how many layer of glass to apply?

4: remove tape.
5: apply gelcoat repair on outside.

 

[sheboyganjohn]

You may want to use poly for the repair. I have seen others post up the same issue. From what I remember it is a similar repair to what you are planning. Not as bad of damage as most think.

 

[chevymaher]

Watch this guys videos.

https://www.youtube.com/watch?v=i9hfpOCnzEs

 

[Jack2048]

Watch this guys videos.

https://www.youtube.com/watch?v=i9hfpOCnzEs

Ok watched the video, three part series. Thanks.
I have come across him before , watched his other videos.

 

[chevymaher]

It is actually really easy to fix. I had staple holes in my hull.

 

[AShipShow]

Agree, Stick with poly as you can then use gelcoat to repair the outside and try to blend and color match it. You're not going to like it, but you should also grind the outside out about 4 inches or so from the hole all around and feather it slightly. Then I would put a strip of 1708 over the length of the cut and then use a couple layers of CSM slightly bigger with each layer. The CSM will help avoid print through of the 1708 to the gelcoat. Then on the inside, fill the cut with PB and grind and feather the inside the same as the outside.

 

[MTJames]

Another idea with the glass: When you mix up the resin (for the inside first), save some extra and chop up the glass in as small pieces as you can. Mix the extra resin and glass to make a "filler" for the gap. If you have good access from the inside, fill the gap with the glass/resin mix then lay a couple layers over the top of that. Paying attention to filling the cut before you glass over it. when it cures up sand down the extra sticking through the cut smooth, then as previously mentioned sand down a few inches around the cut on the outside to allow a couple overlapping layers of glass on top. Feather out as good as you can, seal, prime and paint. I've done the same thing (minus the layers outside of the boat) when filling in holes from bolts/snaps/screws of the previous owner of my current project.

(I've done this numerous times on military aircraft fiberglass repairs, when accessible behind the damage.)

 

[Jack2048]

Mad Props, what you wrote is exactly what was described in the video link provided by chevymaher.

Ok, thanks for all the advice, just a matter of finding time to get to it!