Originally Posted by kta
I've seen a couple boat listings lately for 40+ foot boats that have been knocked off their jackstands and the side of the hull has been cracked open. I'm sure this is repairable, but I'm wondering what the process is.
Can this be repaired reliably? Is it just a matter of cutting back all the damaged edges to make them smooth, then grind/sand in a taper and start laying new glass? Or will entire sections get cut away and replaced all at once? Some of the cracks run all the way up to the deck
joint, so there are serious structural concerns with a repair like this.
Anyone fix something like this? I'd love to read about it!
I've worked on a few major boat repairs
, but not from falling over onto the ground (the repairs I've been involved with are due to point-loading when being hit by another boat).
Short answer is yes, anything can be repaired. Important question: what else is damaged or shifted inside the boat? e.g., bulkheads, liners, deck/hull joints, that sort of thing. Damage like that suggests a lot of other problems will be present in the boat.
Typically what you want to do is work
from the inside out if you can, which requires removing everything on the inside of the boat in the damaged area. If the hull shape has been changed from the impact, you'll need to go back outside and re-enforce/support the hull such that shape is what you want (if you're not certain what the shape was before, then you can pull a form from the oppposite side and create a mirror image - which is a long job).
If you can't work from the inside, you still need to get to the inside of the damage to stabilize and support the repair (e.g., remove the furniture). The downside to working from the outside is gravity is not on your side, and the repaint/fairing area on the exterior will be larger than if you worked from the inside. For damage such as in the photo, fairing may be a moot point but working with resin & glass over your head
is not (for upside-down glasswork vacuum bagging is a nice thing).
Assuming that the hull shape hasn't been changed by the impact then you support the exterior, grind away inside on a 12:1 bevel (not so much fun), and rebuild
the hull from the exterior skin, the core
, through to the interior
skin. Then you get to fair the exterior, the interior
, and colour match...
All of this is a big job; based on the photos, those boats had better be worth of a lot to you for you to take that effort on... it will not be easy, especially if it's your first time at a project
of this size as you will be on a fairly steep learning