Whaler Central - Boston Whaler Boat Information and Photos

Posted by drandlett on 04/05/06 - 5:38 AM

I need to fill some holes on my 1969 Currituck where my SS rails have pulled out of the glass. What method and materials should I use to fill these holes so that I will be able to put new screws in to secure the rail again?

I've filled holes on a 13' whaler work boat with epoxy which held fine, but was not a pretty job. Getting an ample supply of epoxy in the small holes is difficult and I accumulated some drips and runs.

Any suggestions?

Thanks,

dana

Posted by litespeed on 04/05/06 - 4:10 PM

Dana,

What about injecting the holes with epoxy via a turkey injection syrenge? I have heard of some shops using this method. Especially if there is no wood in the area or it has rotted out.

AJ

Posted by link on 05/05/06 - 8:38 PM

I've heard if you drill the hole out bigger than needed (say 1/4")and then put an allen key in a drill and put it through the fiberglass and then spin it to create a cavity in the foam behind the fiberglass. Fill the cavity with epoxy and put bees wax onto the screw you will use and insert it into the epoxy. You should be able to remove the screw when the epoxy dries and have a solid threaded plug to screw the rail into. I will be trying it in the next month and could let you know if it works as my Montauk rail has come off.
Larry

Posted by drandlett on 05/06/06 - 7:37 AM

Larry,

If you do attempt this it would be great if you could tell us how it worked. A picture of the drill allen key setup would be helpful as well, I am a little confused about that.

Thanks

dana

Posted by Tim Gibbs on 06/03/06 - 4:59 PM

WEST has a manual that details this process of cleaning out the wood or foam behind the fiberglass. I've done this to re-build my bow pulpit and re-mount my bow rail. A finish nail with a 90 degree bend in a drill works great to clean out the core. Duct tape if needed on the underside to keep the epoxy in also works great, and the tape glue acts like a release agent. WEST also sells syringes you can fill.
PAM cooking spray also works as a release agent. I put the hardware in a ziplock baggie and sprayed with PAM. Put duct tape on the bottom of the bow rail feet and Wet Set the hardware. Be careful with the hardners if the core is foam, be sure to use slow hardner. The fast hardner can get to hot and damage the foam.
Also Epoxy does not like UV so you may need to gel coat any Epoxy that will be left exposed.