Atom Voyager · video

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Atom removes seven unused through-hulls from a Cape DORY 30C during a refit to reduce maintenance and flooding risks.Watch He eliminates two toilet intake holes, the engine cooling seacock, two cockpit drains, and two transducers.0:04 To remove the seacocks, he cuts slots in the mushroom heads with an angle grinder and removes the bodies with a pipe wrench.1:08 He grinds a scarf into the hull around each hole using a 24-grit disc on a 12,000 RPM angle grinder, thinning the fiberglass edge to allow for a structural patch.1:45 He applies 1208 biaxial fiberglass cloth with US Composites 635 epoxy resin and a three-to-one medium hardener.4:26 He fills the holes with colloidal silica-thickened epoxy, then layers progressively smaller fiberglass circles—eight, seven, six, and five inches—to match the scarf taper.5:13 After curing, he sands the patches flush and applies a fairing compound similar to West System 407.11:16 A final coat of epoxy resin seals the repair before priming and anti-fouling.13:39

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