[Public-list] Filling Holes

[Roger L Kingsland]

Mike,

West System has a great book on FG repair that says one should bevel both 
sides of the hole and build up with multiple layers of cloth which I did for 
the below the waterline stuff.  On deck I cut out pieces of fiberglass 
(usually round) to fit in the holes (I have a refrigerator and found pieces 
from the original ice box liner when I removed it so I used the liner for 
filler pieces).  I fastened the fillers to 1x2s that spanned across the hole 
(to hold the piece flush) and filled the seams with peanut butter 
consistency epoxy.  After that cured, I removed the 1x2s and filled the 
seams under where they were.  I covered the back of the hole with FG cloth 
and used a syringe to fill any void from the top.  I did several holes, 
mostly round.  Biggest one was where I cut out the "bump up" in the cabin 
top that healed the little cowl vent above the head.  Don't know if boat 
flexing in gale force winds will cause upper seams to crack but figure I can 
grind them out and add cloth tape and epoxy later if they do.

One thing that you might want to consider.  If it seams that the void should 
have been filled about 20 syringe fulls ago, there might be a remote chance 
the bottom of the patch is leaking and all the epoxy is running down the 
bulkhead below, across the cabin sole and into the bilge which will take 
about two hours to clean up with thinner than makes you higher than you ever 
were in college.  It least I think that might possibly happen.

Roger

(please note my email address has changed to r.kingsland at ksba.com)
Roger Kingsland
Managing Partner
KSBA Architects
N40°- 27.83'  W79°- 57.99'

(412) 252-1500 x101 office
(412) 779-5101 cell
----- Original Message ----- 
From: "Meinhold, Michael J" <MICHAEL.J.MEINHOLD at saic.com>
To: "Alberg 30 Public List -- open to all" <public-list at alberg30.org>
Sent: Tuesday, March 14, 2006 10:02 AM
Subject: Re: [Public-list] Filling Holes


> Thanks, George.
>
> I would do this for any structural element that needed repair, but is it
> neccessary for filling the holes in the compass cutout?  I presume laying 
> up
> 3 layers of mat and cloth would raise the surface 1/4 inch or so, and it
> would be difficult to fair it out over such a small space.  Would epoxy 
> have
> any tendency to pop out of a hole like this?
>
> Mike
>
> -----Original Message-----
> From: public-list-bounces at alberg30.org
> [mailto:public-list-bounces at alberg30.org]On Behalf Of George Dinwiddie
> Sent: Monday, March 13, 2006 6:52 PM
> To: Alberg 30 Public List -- open to all
> Subject: Re: [Public-list] Filling Holes
>
>
> Meinhold, Michael J wrote:
>> I am relocating most of the cockpit controls back to their original
>> locations, leaving a set of 1/8 to 1/2 inch holes in the compass cutout. 
>> I
>> also removed the compass.  I would like to fill all these, along with a
> few
>> others in the cockpit.
>
> Mike, if it were me, I would just do a polyester resin layup.
>  1. Grind an 8-to-1 bevel around the holes.
>  2. Tape a piece of plastic, or a board covered with plastic sheet or
> wax paper under the holes in the bottom of the compass well (to prevent
> droops and drips).
>  3. Cut (or tear) glass matt (2 pieces) and cloth (1 piece) to fit.
>  4. Lay down a piece of glass matt, and saturate well with resin.  (I
> use a cheap paint brush.
>  5. Do the same with a piece of glass cloth.  Then again with glass matt.
>  6. Fill any low spots with glass matt, the same way.
>  7. Let that kick off, but don't wait overnight.
>  8. Fill the rest of the way with fairing putty (also polyester based).
>  9. Now let it kick overnight.
> 10. Sand and paint.
>
> A small area like that is a pretty easy job.  The hardest part will be
> sanding in that confined area.  If you do the grinding ahead of time, we
> could do the job on Maintenance Weekend.
>
>  - George
>
> -- 
>  ----------------------------------------------------------------------
>   When I remember bygone days                         George Dinwiddie
>   I think how evening follows morn;            gdinwiddie at alberg30.org
>   So many I loved were not yet dead,           http://www.Alberg30.org
>   So many I love were not yet born.
>                'The Middle' by Ogden Nash
>  ----------------------------------------------------------------------
>
>
>
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