Here I started removing all of the bottom paint from the transom area.
I used Acetone to begin with which removed a lot but not the thicker areas.
Fortunately there was only one or two coats of the same color bottom paint.
I also removed the 1 1/4" brass drains tubes as I wanted to replace them also.

I purchased 2 new clam shells for the fuel tank ground wire: Perko Clam Shells Vents
I also bought a new Fuel Tank Ground Plate: Fuel Tank Ground Plate
Here I have all the new parts temporarily installed to make sure none of the screw holes were stripped.
All the remaining holes you see need to be filled with the exception of the drain tube holes of course.

I started filling the 1/2" holes in the transom.
I purchased a 1/2" plug cutter and a small piece of 3/4" plywood and started making some 1/2" plugs.
I coated the 1/2" plugs in epoxy and pushed them into the holes. I only did a couple of plugs at a time in each of the holes and waited a couple of hours before putting more plugs in. This way, the epoxy would set up a few plugs at a time. I used 1 hour epoxy as opposed to 5 minute epoxy as I didn't want the area to get too hot.
I also removed the rest of the bottom paint by using a palm sander.
I put a pencil line on the transom for the eventual bottom paint. Make sure this line is straight. The prior line on this boat was not straight across the stern. Go Figure. I used a long straight edge to make sure it was straight.
After removing the rest of the bottom paint I found more holes that had been previously repaired. These holes were for, who knows how many, transducers. These holes were on each side of the stern. Some of these old transducer holes were leaking slightly so they needed attention at this time. The gray repairs were the prior ones.

The holes are totally filled now with plugs and epoxy. They will not leak anymore.
To finish off the top of the plugs, I used Spectrum Gelcoat patch paste in the correct color.
Here is the information on the Spectrum kit. F552203, Boston Whaler Desert Tan 1972-1993, B#1496
I put a thin coat of the patch paste in the hole and let it dry. I did not let this paste get outside of the hole being repaired. Wipe off any excess immediately from around the hole.
I then put on a thin final coat of the patch paste over the holes only, using a flat plastic putty knife. The paste in the holes is now flush with the rest of the hull. Again, wipe off any excess from around the edges of the holes.
Black bottom paint was applied using a roller. This paint matched the existing paint on the rest of the boat.

And here is the completed project.
All the holes are filled and new bottom paint on transom area.
New 1 1/4" brass thru-hull fittings.
New clam shells and new fuel tank ground plate.
Note: Do not get any paint on the fuel tank ground plate (remove the plate for painting) or the brass drain tubes or their O-rings. That is why I left a small area around the brass drain tubes. You don't have to leave it as big as I did but my wife liked it that way.

Photos and Article by Joe Kriz