The protective coating on fiberglass is usually gelcoat, a resin-based material that is used to create a smooth, durable, and high-quality finish on the surface of fiberglass-reinforced composites. When we see a bit of it popped loose, we take a close look, as there could be damage to the fiberglass underneath, which is the case for several spots on our 60 year old Alcort Catfish hull.
This little chip here...
...is over a fractured piece of fiberglass...therefore a spot for leaks.
Next we used some Great Stuff expanding foam to secure two loose foam blocks in the portside hull. The blocks are used both as structural members and for added flotation, they are made of closed cell foam sheet and 2 part marine grade expanding foam.
We made sure to not completely fill a space with the expanding foam, and left channels for water to drain so that the foam does not absorb standing water. While all of the foam is closed cell, if it is left sitting in water it will eventually absorb the water and gain 8 pouns per gallon of weight.
A combo that you will see a few more times, THIXO PRO epoxy adhesive and different types of fiberglass cloth used to repair the hull. The thick weave woven roving is the type of weight and weave used to build the Alcort hulls back in the 1960s.
We could mix up resin, hardener and filler to make this mix, but that takes time , measuring and mixing... a lot of mixing. We made up this batch of thickened adhesive in seconds.
The cardboard backer, epoxy, fiberglass and strings go into the hole...
...and then the patch is unfolded and the strings used to pull the patch flush to the inside of the hull. For a large patch like this I could have added some stir sticks under the cardboard to help pull everything flush, because 2 strings were barely enough to hold th patch as the cardboard softened and the strings move in a bit. But it worked for the intended purpose.
Video: https://youtu.be/saxLZF_2Yd0
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