Sam Holmes Sailing · video

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Fiberglass repair techniques for filling decommissioned through-hull openings and instrument cutouts involve creating a 12-to-1 bevel around the hole to ensure structural integrity.8:47 After removing old through-hulls and seacocks, the process requires backing the opening with a plywood plate, then layering 9-ounce woven fiberglass mat saturated with epoxy.1:35 Using a template traced onto plastic allows for pre-cutting tapered patches, which are applied from smallest to largest to build up the necessary thickness.4:49 A peel ply layer applied over the final wet patch creates a smooth finish and absorbs excess resin.6:09 For stubborn stainless steel screws that resist drilling, an angle grinder serves as the primary removal tool.0:26 A 3D-printed through-hull removal wrench can successfully extract seized fittings.7:40 Successful lamination benefits from a three-person workflow: one person cutting material, one applying resin, and one squeegeeing the layers.9:57 Proper preparation of tools, including spreaders, rollers, and acetone, remains critical for managing the curing time of epoxy.11:33

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