Sam Holmes Sailing · video

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To eliminate persistent deck-to-hull leaks on a Cape Dory, the owner removes the original tow rail and rub rail, exposing a compromised flange joint.4:05 After grinding the area down to the fiberglass, the project involves filling hundreds of old hardware holes with epoxy and applying a six-inch strip of fiberglass tape over the joint to create a watertight seal.6:01 The process requires careful temperature management, as the use of West System 205 Fast Hardener in 80-degree weather causes the epoxy to cure rapidly, while cold conditions necessitate the use of radiant heaters to ensure proper bonding.14:21 The repair includes using peel ply to achieve a smoother finish and fairing the surface with TotalBoat fairing compound.8:42 By removing unnecessary deck hardware and sealing the hull-to-deck joint, the owner aims to prevent water ingress that previously caused interior leaks during heavy seas.18:24 The project demonstrates that using peel ply during the initial layup significantly reduces the labor required for sanding and fairing.8:42

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