How to Fill a Guage Size Hole

Discussion in 'Restoration Projects & Questions' started by tj309, Sep 5, 2015.

  1. tj309

    tj309 Composite Specialist

    Joined:
    Jul 19, 2010
    Messages:
    399
    Location:
    LA (lower Alabama)
    Boat Model and Year:
    1972 18' Hydrodyne
    Ski Team:
    Former Hodag Water shows
    This particular hole was a miss drilled gas cap hole so it is horizontal instead of vertical. Most of what you will see will apply to vertical gauge holes. 20150904_170918.jpg 20150904_170908.jpg I cut a circular plug out of 1/8 inch luan and the first pic you can see it is jellied in from the bottom. The second pic shows the plug from the top. You can see the balsa core of the deck around the perimeter. Next I cut cloth then put four layers in with resin. The idea here is that the resin will permeate the balsa core for a strong bond. 20150904_180407.jpg if you just put pure resin in a space like this it will be brittle and crack like window glass. Cloth is very important. More to follow when the resin cures.
     
  2. tj309

    tj309 Composite Specialist

    Joined:
    Jul 19, 2010
    Messages:
    399
    Location:
    LA (lower Alabama)
    Boat Model and Year:
    1972 18' Hydrodyne
    Ski Team:
    Former Hodag Water shows
    While the resin is curing the difference between this hole and a vertical hole is that instead of a thin plug you should use a plug slightly thinner than the hole and do both sides with jelly. If you want to fill a 1/2" bolt hole in a transom find a 3/8" dowel and cut it slightly shorter than the thickness of the transom and wrap it with resin impregnated cloth and shove it in. Then finish the ends as explained later in this thread.
     
  3. tj309

    tj309 Composite Specialist

    Joined:
    Jul 19, 2010
    Messages:
    399
    Location:
    LA (lower Alabama)
    Boat Model and Year:
    1972 18' Hydrodyne
    Ski Team:
    Former Hodag Water shows
    Bottom side sanded. top side jelly in. This is where it is the same as a vertical dash. Sanding next. 20150904_204046.jpg 20150904_204921.jpg
     
  4. tj309

    tj309 Composite Specialist

    Joined:
    Jul 19, 2010
    Messages:
    399
    Location:
    LA (lower Alabama)
    Boat Model and Year:
    1972 18' Hydrodyne
    Ski Team:
    Former Hodag Water shows
    I sanded and layed some bondo. 20150905_203937.jpg Then I re-drilled the hole. 20150905_204454.jpg 20150905_204454.jpg sorry about the double pic. What you see on the right is original deck core. On the left is from bottom to top you see jelly, luan fill wood, glass, original deck glass, and my work.
     

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