Aside from a mis-match in the gelcoat
, the removal
and filling isn't that difficult. I've done a few of them on the bottom of various boats. While the ones I did weren't that large, IE 1 inch instead of 2 inch the process is the same.
First remove the fitting. Then bevel out the hole on a 10:1 ratio. IE 1/4 thick skin would need a dish about 2.5 inches larger on each side. So for a 2 inch hole, you'd be dishing out a 7 inch circle. Take it down to feather thick at the hole.
Next you put a backing plate covered with wax paper up against the back of the hole. Hold it in place with a strut and wedges.
Then start cutting out disks of woven roving and chopped strand matt in alternating layers. CSM/WR/CSM/WR/CSM/WR.... until you have enough to fill the dish completely. each disk will be slight larger than the last one.
Start wetting down the dish, with epoxy
, and place the first layer and wet it out. Get as much resin out as you can so its nice tight, then keep adding alternate layers.
Once done, sand it with a block and sand paper in a circular motion so the slight curve of the surface isn't lost
. Go slow here and check by eye to make sure you aren't getting a flat spot.
Finally you can finish it off with interprotec 2000, and sand with increasing grits of wet n dry paper.
Once done you should see it blend in with the original glass, and then all you need to do is put on matching gelcoat
. That you can either do yourself with a compressor
and spray gun or hire a contractor.
It might not be a perfect match but it will be solid.