Console Repair- Filling old cutouts.

[Fletch170]

Hey guys, Starting work on the console on my newest project (Busted, not an Aquasport). When I've filled larger cutous before, I placed coring on the backside, glassed it in place, then built up layers of glass on the outside, patched faired, primed painted etc.

What I was thinking, was laying up several layers on plexiglass, then cutting the fiberglass to fit the cutout in the console. This then fills the void, with glass, no coring.

My question is, how is the best way to go about doing this? Am I making more work for myself?

[seabob4]

Seems to me Christian like 6 of one, half dozen of the other...

I do it your first mentioned way.  Back-glass, bond coring in place with dura-glass, a few layers of glass to bring it past flush with the face, sand, gel, sand, buff, off you go...

[RickK]

On mine I removed all the old coring and installed new, then filled/faired the gap on the face (like you mentioned as your first step).

[Fletch170]

Hey guys,

Sounds like I'll just stick with what I know! I'll simply use coring then f
Glass. Thank you!

Also,

Is there a shelf life for poly resin? I have a 5 gallon bucket that is almost full, left over from the 17 build.

[RickK]

Hey guys,

Sounds like I'll just stick with what I know! I'll simply use coring then f
Glass. Thank you!

Good idea.

Also,
Is there a shelf life for poly resin? I have a 5 gallon bucket that is almost full, left over from the 17 build.

I was told by the poly supplier that poly starts to harden the minute it is made.  You can go to a supplier and buy "sale" poly and that is usually poly that has had the lumps that start to form as it ages strained out and needs to be used NOW.  I walked out in my workshop the other day and saw the sides of the 5gal poly pail sucking in. It's a few months old and I have been using it sporadically. I opened the cap and let it relax and then resealed it.  I need to use this stuff up soon and need to watch out for lumps.
Anyway, watch out for lumps.

[Fletch170]

Roger that. I'll check for lumps.

Pretty much good advice for life all around.

As always, you guys are the best. Check back with the Hydrasport build soon. As soon as the snow is melted, the console is getting removed, as is the motor and she's off to glass blasting .

[TheKid]

I just used a starboard cover. Left console as is. Installed and drilled/cut through both. Ended up looking good.


Backfill and glass would be ideal. But my boat is a beater. It floats/runs and has never let me down. The cosmetics are just that to me, cosmetics.

Most my money goes into functional improvements like electronics, arch and top.

[SaltH2OHokie]

I've got a fair amount of holes from previous owners, etc that I want to tidy up between the 19-6 and the 290.  Is there any straightforward how-to for someone like myself (never done fiberglass, but fairly mechanically inclined/pick things up quickly/etc.) that would go step by step?  Essentially I understand what I'm reading, but when I think it through, I keep envisioning ending up with a hump where my patch is...say the console is 1/2 material with glass over it...do I just use 3/8 material held flush underneath?  How does the transition happen between patch and existing without showing?

[SaltH2OHokie]

Answered my own question...west system had a detailed manual that spelled it out just the way my sometimes simple mind needed it spelled out.

If/when I tackle any fiberglass projects I'll post my results (and likely questions).