We cut out the plug from 1/4 inch thick AB marine grade plywood. The masking tape was used to make the pattern, and we cut the plug a little big so we could sand fit it to final shape on ZIP.
The backer plate had to be cut into 4 pieces to fit around the internal stringer and frame.
We used TotalBoat THIXO Wood to fasten the backer plates to the inside of the hull. THIXO is a 2 part thickened epoxy and hardener that comes in a caulk tube and mixes in the mixing tip. A 18:1 High Thrust caulk gun makes disoensing the product easier.
Lots of clamps with light clamp pressure until a small bit of epoxy squeezeout is seen. Too much clamp pressure can squeeze all of the adhesive out of the joint.
Clamp video: https://youtu.be/2KFFkbzn2Sc
Even though it is a different piece of plywood, we are trying to keep the grain running the same direction on the patch as the it is on the deck. We marked the grain on ZIP onto a sheet of poly, then moved the poly over to the plywood sheet to align the blue tape pattern with the grain on the plywood where we would cut the plug from.
Skipper's new DeWALT 24V XR cordless jig saw, wow it is nice! More on that tool later.
We cut the plug just a little outside the pattern line so we can do the final shaping on the boat.
Log of ZIP.
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