Repairing a large hole in the hull.

A tree fell on my sunfish, and pushed it down on the roller on my trailer. It busted through in front of the mast step. How should I go about repairing this? I have a hull a friend gave me that I could possibly cut a section out of, though I prefer not to cut it up. If I did cut out a section, should I put the piece in from the outside and reinforce it from the inside through an inspection plate? Any ideads are appreciated!

Joey

Douglas Zargham made an excellent video if a similar repair that he successfully completed. I think if you have a hull that you can make a mold of for the missing area, even if it is over sized, you can use his post and video to complete a keel repair.

Be aware that you'll be into it for a couple of hundred bucks in material but you will be able to do several repairs in the future if need be.

Forum Thread: http://sailingforums.com/threads/sunfish-hull-repair.22416/

Video: http://youtu.be/S398W4GfQIM

You can "build-up" a fiberglass piece from scratch.

For the exact curvature needed, use the top of your deck to form it. Use wax paper to separate the piece from the deck. Glue or pop-rivet the new piece inside, and build up the deck to be flush again.

Joe, I would follow the video mentioned in "Shoreline99's" previous post.

http://youtu.be/S398W4GfQIM

The video is well produced. Yes, create a patch by casting on top of "Betty" and transfer that patch to your compromised hull. Roughen the surfaces that will be used to create the bond (ie. the inside area of your hull and the top face of your patch piece). Your hull hole is big enough to get your hand into with some #36 grit paper. Wear gloves. See my photos on the Sunfish Yahoo forum. I work in a skinnier hole. West epoxy with some 406 silica and use pilot holes to screw together your patch piece from inside your hull to your hull.... as seen in the video. Your hull fix will be simple, honestly. Best of luck.

Joey, any headway on the keel impact area or the transom overlay idea? I hope all is well at your home port. Cheers from Kalamazoo

Hey Pete!

All is well over on my side of the state! Actually... I bought another sunfish! I have a fleet of three now! This one was 150, with a sail. Mid seventies AMF boat, in floating condition. I WILL sail this fall! Looks like I have some fiberglass projects for the winter...!
Thanks for all the advice!

Joey

Great find...........................Full Sails Joey............. I am wet suiting till the end of October then seriously preparing the ice boat for hardwater..... Cheers