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Repairing a Crack in the Keel — This Had to Work
July 25, 2026 · 22 min · 2K views · Puerto Madero, Tapachula
What this video covers
Natasha and Kyle perform a structural keel repair and complete the final pilot house window installation on their boat while anchored in Tapachula.1:26 To address a crack in the keel, they grind out a V-shaped channel, drain water-filled voids, and fill the gaps with thickened epoxy.5:42 They then apply multiple layers of fiberglass mat using limited supplies, including standard epoxy and brushes, while working in high-wind conditions.14:04 The repair process involves trial-and-error layering, sanding, and tapering to ensure structural integrity despite a lack of specialized fiberglassing tools or slow-cure hardener.10:42 Simultaneously, the crew finishes sealing the last of the pilot house windows using butyl tape and SikaFlex, overcoming issues with frame corrosion and rapid sealant curing times in the heat.3:59 The project concludes with the final fiberglass layers applied to the keel and the repair of a secondary blister.19:35 Structural repairs with limited resources require careful preparation of the substrate and iterative layering of fiberglass to achieve a solid, cured finish.
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