Category Archives: Boat Repair

Appledore IV makes her way upriver after a cruise on the Saginaw Bay with her restored topmasts in place.

Repairing Rotted Topmasts on Appledore IV

by Randy Zajac

Above: Appledore IV makes her way upriver after a cruise on the Saginaw Bay with her repaired topmasts in place.

The Appledore IV is an 85′ LOA topsail schooner owned by the non-profit organization BaySail, based here in Bay City, Michigan. She is licensed to carry 52, including a captain and crew of three, on educational tours of the Saginaw Bay and Lake Huron. The main topmast and the fore topmast on Appledore IV were found to have rotted wood when they were inspected in the spring of 2006. Once the topmasts were taken down from the boat, they were brought into the Gougeon boat shop for paint removal and further inspection. Continue reading

International 110 sailboat restored

Rebuilding an International 110

By Tim Botimer

Above: Tim’s International 110 sailboat. After winning the National championships, he gave her a new coat of paint.

I first got into International 110 sailing 15 years ago and soon bought an old fixer-upper boat. After sailing it for a couple of years in a decrepit state, I made the decision to fix it right. I had worked with WEST SYSTEM® products before, and I was pretty familiar with the product line. I had done significant repairs on a 1965 plywood Thunderbird and a 1950s vintage Flying Dutchman, which incidentally was one of the original test boats when Jan and Meade Gougeon first came out with the product. I had never tackled anything on the scale of the 110 project, and at the time it was the only boat I had. Continue reading

Bounty Hunter after sheathing with WEST SYSTEM.

Giving BOUNTY HUNTER New Skin

by Patrick Ropp—GBI Technical Advisor

Above: The 65′ strip-planked Bounty Hunter after sheathing with fiberglass and WEST SYSTEM Epoxy. After 5 years, she still looks as good as she did then. In addition, her new fiberglass skin quickly paid for itself through increased performance.

Five years ago, Captain Glenn James decided it was time to make improvements to his Coast Guard-inspected charter fishing boat operating out of Edgewater and Solomon’s Island on the Chesapeake Bay. Bounty Hunter is a 65′ cedar-strip planked hull, a one-off Davis™ hull that was built in 1967 at Harkers Island, North Carolina. The planks are fastened to frames on 16″ centers with monel fasteners. The cedar strips are narrow, less than 2″ wide, and are edge nailed with monel nails and edge-glued. Continue reading

Rebuilding a Rudder

by Barry Duke

Above: The two foam halves of the rebuilt rudder, with the plywood core, are dry fit around the post before bonding.

What started out to be a relatively easy job of replacing the motor mounts and cutlass bearing on my 1983 Nelson/Marek 36 turned into building a completely new rudder. Once I removed the rudder, I had planned on fairing it and applying a WEST SYSTEM® Epoxy with 422 Barrier Coat Additive. barrier coat. However, upon closer inspection, I noticed that the rudder appeared to be bent.

Continue reading

Epoxy vs. Polyester is an important consideration in fiberglass boat repair.

WEST SYSTEM Epoxy vs. Polyester

for Fiberglass Boat Repair

by Tom Pawlak — GBI Technical Advisor

Above: Epoxy vs. polyester in a typical fiberglass boat repair cross-section. 

Even though we’ve been promoting the use of WEST SYSTEM® Epoxy for repairing fiberglass boats (boats made with polyester resin) in our manuals and Epoxyworks for many years, we continue to receive inquiries asking whether it is appropriate to use epoxy for polyester boat repair. Because of the misinformation still prevalent in marinas, local yacht clubs and on the Internet, we felt it was time to restate the case for epoxy. Continue reading

Polyester Gelcoat Over Epoxy

by Jeff Wright — Vice President of Technical Services

Most production fiberglass boats are made with polyester resin, and we’re often asked if it’s appropriate to use polyester gelcoat over epoxy. WEST SYSTEM® epoxy is a wonderful material for repairing polyester fiberglass boats. One reason for this is the ability of epoxy to form a stronger mechanical bond to a damaged laminate than polyester resin. Epoxy also provides a better moisture barrier than polyester resin. Continue reading

The U.S. Customs graphic was restored after the repair was completed.

US Customs Fiberglass Boat Repair

by Rich Simms, NMSC

Above: The US Customs fiberglass boat that was damaged while interacting with suspect violators and repaired with WEST SYSTEM Epoxy.

Vessels used by the Bureau of Immigration & Customs Enforcement (ICE) can be subjected to severe conditions during law enforcement operations. Occasionally, the intense interaction between law enforcement vessel and suspect violators can result in unwanted vessel damage. The damage on this ICE interceptor was the result of an intentional impact by a suspect vessel (Photos 1 and 2). Continue reading

A great tool when you want to prepare fiberglass laminates for epoxy adhesion

A Better Way to Prepare Fiberglass Laminates

by Tom Pawlak — GBI Technical Advisor

Above: The Rapid Strip Brush™ is a great tool when you want to prepare fiberglass laminates for epoxy adhesion.

During a recent inspirational hardware store visit, I discovered a rotary wire brush made by Norton™ called the Rapid Strip Brush™. It is used with an electric drill and produces results comparable to bead blasting or a needle scaler. The package says it can be used to abrade metal, masonry, and fiberglass. I immediately thought of a fiberglass application that I wanted to try it on. Continue reading

repairing machined holes in fiberglass

Repairing Machined Holes in Fiberglass

Technical Staff Report

Above: When repairing machined holes in fiberglass, whether screw or a through-hull fitting like the one for the pictured seacock, your strategy will depend on the size, purpose, and location of the hole.

First, we will classify the types of holes we are discussing as ones that are round and have been machined, probably with a drill, as opposed to punctures and cracks incurred from damage. The reasons they may need to be repaired are numerous: refitting, resizing, removing obsolete equipment, or mistakes. When repairing machined holes in fiberglass boats, the challenge is to determine an appropriate repair strategy. You want a repair that is safe and adequate, but also realistic. You want to ensure that the repair is strong enough for the anticipated worst-case load and err on the side of being conservative. Other things to consider include the costs in time and money and the skill required to perform the repair. Continue reading

Installing a Teak Deck on ZATARA

by Ken Newell
Epoxyworks 20

Cover Photo: The intricate plank layout of ZATARA’s finished teak-covered cockpit, before the hardware was reinstalled.

The Zatara refit project began two years ago when my partner Steve Gallo (a mortgage banker) and myself, Ken Newell (a materials engineer), decided that we wanted something to do with our spare time and money. What we didn’t realize was the level to which the refit project would absorb every weekend and every non-critical dollar we had and cause our significant others to chastise us for our obsessive behavior. Continue reading