Fibreglass repair

[pzmaria]

Hello owners. Looking for your experienced advice how to approach this project. First of all how the water is getting inside this area. Second, looks like there is a steel pipe that is expanding with rust causing the crack to grow. What is this pipe (pipes) for, what is the purpose for being there. And finally how to approach this repair. I'm quite comfortable working with fibreglass. Any suggestions and pointers greatly appreciated.
pzmaria.

[Cyrus Safdari]

General rule of all fiberglass repair applies: grind it out, fill it in, glass over, sand fair.

[Cheechako]

I cant tell what's going on there. Pipes? maybe someone put in drain holes due to water accumulation?
But I'm betting That is wood that is rotten which was covered by gel coat or thin glass.
I would remove the slider, and tear it off and fix properly. You could do it in teak and not have to do any glassing at all.
Sometimes getting the slider off is a mystery. Sometimes just removing a trim piece other times they have other schemes.

[pzmaria]

Strange but it is definitely a steel pipe. I even checked it with the magnet so it is carbon steel and the rust on the pipe is spreading fibreglass. Is it there for reinforcement of the opening? Just trying to get as much info as possible before I open this disaster.

[Cheechako]

That is strange, almost like they used it for filler to form the glass around or something. Boat builders!
I'd probably redo the whole thing as I mentioned earlier. But that's me.
There is a product called "kitty hair" which is fiberglass resin with chopped glass in it so it's the consistency of putty or etc. You could just fill with that and grind flush and paint for a cheap fix. The pipe does nothing anyway but fill space.
But you need to figure out how the water is getting in there.

[Colin A]

The rust on the pipe is likely going to be an issue. I thin k a permenant fix may involve taking off the hatch cutting away the damaged are and pipe and rebuild with plywood and new glass.

[pzmaria]

Decided to make this repair. Just opened the hood over the hatch. Found tons of silicone and dirt. Started to clean all areas and open all existing screw holes to fill them with mixed epoxy/fibreglass and re-drill them later. Next will be drilling small holes away from the damage to establish damaged area under fibreglass.
It's the first time I'm doing that extensive repair so, if there is anything that I'm doing wrong please don't hesitate or feel bad to make a comment.

[gamayun]

A friend of mine with a Hunter 41 had a hatch that constantly dripped into the boat from the back end of the hatch (toward the bow) and it was rotting the wood in that area. It kinda looks like what you have got going on. You probably need to fix the faulty hatch design no matter what eventual fix you make to the fiberglass. I'll try to ask him about the details and get back to you, but IMO, you need to figure out how to redirect the water from around the hatch.

[Cheechako]

Good you are going at it the right way. Keep us posted!

[Suijin]

I'm going to guess that the pipe was added as reinforcement by some previous owner during a previous repair. If it were me I would remove it entirely and if the coachroof needs reinforcement, build in a new stiffener. A few strips of G10 laminated together would be my first choice. Strong, relatively easy to work with and create the required shape, and impervious to moisture.

If the pipe extends out to the plinths for the traveller there is a possibility it's a stiffener for them but I find it hard to believe that any boatbuilder would have incorporated steel pipe like that, even encapsulated.

[pzmaria]

What is G10?
Being in Mexico don't have access to many materials like balsa for example. Talked to a local carpenter and he is suggesting local tropical wood. They call it "machichi". Kind of a redish in colour, very hard but quite light at the same time, water and termites resistant.

[pzmaria]

As "gamayun" member mentioned, decided to look for low spots. Using water in a hatch channel found a low spot just in front of the traveller on both sides. I'm planning to cut thru on the outside of the channel and re-laminate it to create a drain. It will be hidden under a teak decorative strip.
....
The good news is the damage seams to be just local to the pipe. Made a bunch of small holes and core looks clean. At first glance it looks really ugly, but it is the rust on a steel pipe that is spreading fibreglass.