The On Deck Channel · video

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Drilling through a cored fiberglass deck — two layers of fiberglass sandwiching a foam or plywood core — requires an oversized hole filled with thickened epoxy before the final fastener hole is drilled.0:03 Ryan demonstrates the technique used when mounting solar panel brackets on the boat's stack: drill a pilot hole, then drill an oversized hole (e.g., a 5/8- or 3/4-inch hole for a 5/16-inch fastener), tape the underside to capture epoxy, inject 3M 610 thickened epoxy from the top, wipe flush, and let it cure 24 hours.2:04 The next day, drill the final, smaller center hole through the cured epoxy plug, then through-bolt with CT1 adhesive sealant.2:13 The epoxy plug serves two purposes: it prevents water from reaching the core if sealant fails, and it acts as a compression stop so over-tightening cannot crush the core or crack the gelcoat.1:00 For solid fiberglass (no core), the epoxy plug is unnecessary; the critical step instead is countersinking the hole so side-loading from the fastener does not crack the gelcoat and so sealant can seat properly around the fastener head.3:10

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