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I have a outrage v-20 and use it in the Maui waters a lot. One of the things about Maui leeward waters is that its flat as glass in the morning when you leave the boat ramp and when you come home you have to slam through what I call lake chop. This is small short spaced waves generated by winds, some times in the range or 20-40 mph. In the smaller chop the whaler will ride above these waves but will get constantly slamed or pounded. Eventually this pounding made a crack under the port side of the hull about two feet long running front to back right about mid-ships or where the hull would take the most punishment. This was about six years ago. I patched the outside of the hull with two or three lalers of glass and resin and the inside of the hull with another two or three layers of glas and resin. I re foamed the hole that I doug out with closed cell two part foam from fiberglass hawaii and then resealed the deck with fiberglass and resin. The upper patch is hidden by the floorboard deck.

The boat is once again leaking, but only from the front of my patch and the back end of the patch. I think the inner foam is deterioratered because small particles that look like sand come out with my bilge water. This boat also does not have the gas tank because it corroded thru last year and was removed. The removal may have caused the hull to flex more.

What ae the proper procedures to repair this crack?
And how can the wet/waterlogged foam be removed?
I estimate that 25% of the port side is waterlogged and de-laminated.

The boat was used for 12 years by me for bottom fishing in the Maui waters and became a work boat. Its a very strong and reliable boat. With as little maintenence that I gave it, It always brought me home.

She Is now going to a new owner and I would like to tell him how to fix her up to last him another 15 years.

Is there articles already on this subject.

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You have more than a crack in your (or the new owner's) hull there is a MAJOR structural issue with the boat it will need to be fixed. If left untreated will this will ruin the hull if it is not already ruined. If you sold the boat you will want to inform the owner about the hull needing to be repaired before he uses it. I would hate to see this thread end up in court because someone was hurt or the owner feels the boat was misrepresented.

Sounds like he will need to first pull the boat and remove the effected area's fiberglass and deteriorated foam and figure anything with in a foot or more of the area might need to be taken out as well. Drill some holes about every foot along the keel to help drain water outside of the effected area. Trust me water moves through the hulls foam and will settle in the lowest spot. Let the hull sit with the keel facing down till it stops draining.

Next flip the hull up-side-down with the keel in the air and let it sit like this for some time. It will help any remaining water move away from the area the repair will need to be redone. wait until the effected area is dry to the touch. Probe it with a wood dowel at make sure it is dry for a couple inches inside the hull.

Next survey the area and if you need to remove more to get back to glass that is still bonded with the foam do so. Once you have gotten back to an area where the foam is bonded to the glass and the deteriorated foam is removed you can now start refoaming the area. Mix and set the foam pour it in place and let it expand out.

Now he will need to resurface the new foam back to the shape of the hull. Using long straight pieces of wood check for low spots and deep voids. If there are some, refoam.

Now once the foam is shaped you can begin reglassing the area. Start with resin and cloth till you get a good shape started and then use resin and chopped mat for the other small voids.

Once that is done and shaped you can regelcoat.

Yes it is a lot of work and a lot of money but, it can be done.