Going to fix up "Crystal," a 2003 Vanguard Sunfish. She got damaged during a storm and need repairs to punctures and abrasions in her hull.
Transported her to the house, I think she is secure...
The keel was damaged by rocks on a seawall. We will use a blind patch for this repair. A blind patch is a cardboard/fiberglass/epoxy backer that gets inserted into the hull and pulled tight, once it dries you can build up layers of fiberglass to repair the hull.
Dock bolts punctured the chine.
More seawall damage.
We use a diamond file to remove broken gelcoat and crushed fiberglass. File til you get rid of the loose fiberglass cloth fibers and loose fiberglass. Then fair the edges of the hole, that creates more surface area for the replacement epoxy and fiberglass to attach to. We like epoxy resin vs polyester because it bonds well, has better structural qulaities and doesn't smell as bad.
You can file all of this away or use a spiral saw to cut the big chunks off. Set the drill bit to only cut the hull, if it is too deep it can cut internal parts or the cockpit.
Filed, sanded and faired for patch.
The finish on the hull is oxidized, stained and sunburned. We will sand off the oxidation, clean the stain with Iron Out, wet sand and wax. Patched areas will get touch up coverage of paint.
Half of the port hull sanded and started on the starboard side.
14 Feb 2015: Crystal awaiting repairs. But a note here is that it is nice to have a spare cover to protect the boat while work is being done, in our case from pine sap, flying pine cones, dive bombing birds, bugs, dirt etc...that way work doesn't have to be redone.
04 Mar 2015: Crystal got to be the first boat on the new finishing dolly.
Feathered the keel with a dual action sander. The paint stick will be used to reinforce the backer patch.
11 Mar 2015: Trimming out some heavy weight buckram cloth, about an inch wider all around than the repair. The buckram is stiff fabric that will add stiffness to the repair while it dries inside the hull. It also will keep the tie strings from pulling through the epoxy wetted cardboard.
Traced the repair area onto the cloth so we know where to put strings through. The strings are used to pull the patch tight against the inside of the hull while it dries.
Here is the blind patch, which consists of a paint stick, buckram, cardboard, woven roving fiberglass, epoxy resin, bridging filler and strings.
Here is the blind patch, which consists of a paint stick, buckram, cardboard, woven roving fiberglass, epoxy resin and strings.
Blind patch inserted into keel and strings tied tight to pull it into position against the inside of the hull. Then I wedged sticks into place to pull it tight and made sure epoxy was contacting the hull all the way around the edges.
Cut fiberglass for blind patches about 1 inch wider than the hole. Clean broken fiberglass away from edge of hole with a file and clean inside the hull with acetone or mineral spirits.
Cut a piece of cardboard to pull the fiberglass flat against the inside of the hull. This is a test fit, it need string or wire to pull it back flat inside the hull.
Used a screwdriver to poke holes for the strings (whipping twine).
Patch pushed through and pulled tight against inside of hull. Tie the string off to a stick or more cardboard.
I used Marine-Tex on the keel gouges. Main reason is that's what I had. Pettit EZ Fair would be easier to sand.
Blind patch drying.
16 Mar 2015: The deck is oxidized, but not too bad. Waxed it with 3M Fiberglass Restorer and Wax, used different bonnets to apply and remove the wax, then buff and polish the surface.
Replaced the drain plug.
Peeled off an old Sunfish decal.
Used Marine Tex epoxy putty then Pettit EZ Fair to fair the repairs. Sanded with 120 grit on a DA sander then sprayed 4 coats of Rustoleum Gloss White.
Sat in the moaning chair for a while after some paint bubbled while spraying the hull.
17 Mar 2015: All is well, last coat drying.
18 Mar 2015: Bought a new random orbital sander.
Applied a new Sunfish sticker.
Crystal loaded up on her trailer, waiting to go back home!
Great work.
ReplyDeleteThanks Rob! She was fun.
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