Massive hole....

Jizm · 06 December 2006, 16:12

I am just starting to refurbish my Tornado and there is a large hole in the side of the console which used to allow access to the fuel tank. How do I fill this so it is nice and strong and gives a good finish. I am painting the boat white anyway so colour is not a problem. I was thinking of flowcoating the inside of the aluminium plate, glassing up the inside, then removing the plate? Any experts out there want to give me some advice? Will the GRP adhere to the ally as I have no experience using wax or releasing agent?
Ta
Jiz

Aidan · 06 December 2006, 17:03

Quote:

Originally Posted by Jizm

I am just starting to refurbish my Tornado and there is a large hole in the side of the console which used to allow access to the fuel tank. How do I fill this so it is nice and strong and gives a good finish. I am painting the boat white anyway so colour is not a problem. I was thinking of flowcoating the inside of the aluminium plate, glassing up the inside, then removing the plate? Any experts out there want to give me some advice? Will the GRP adhere to the ally as I have no experience using wax or releasing agent?
Ta
Jiz

Hi Jiz, Acetone is the standard prep for Resin. Be careful how you store as it has a flashpoint of 24deg as I recall. After that, Resin sticks to nearly everything except Silicone Oil WD40 etc.

However, depending on teh colour you paine, how about different idea.
You do not need huge reinforcing and its not a strategic fix,
Depending on the colour you paint,I would cut perspex sheet to size and bond using resin to Both sides using bevelled edges on Perspex (heavy duty).
You can use Carpenters cramps to Hold tight when bonding.

A cleaner way may be to use Stainless Steel and do same other side so it looks cool.
Other than that you can get a "Cable Coller" to fit hole from Any marine shop
You will see these here the control cables leave bulkhead to go to engine on "nicely finished boats" this is a water tight fit and the seal and spray/Paint alloy after either acid dipping in Galvenising plant (5 pound max if not for free)

Thats only my twopence worth, hope it helps. There will be thousands of ways of finishing but if its painted properly you will not see it.
You could also just acetone plate (get from Chemist) and fit coller or plastic plate in little hole, paint in resin for coat, then gel coat paint the lot.
You will not even see it.

Aidan

Jizm · 06 December 2006, 17:20

Sorry, obviously I don't want it to stick to the ally plate, just use that to get a smooth finish, a bit like a partial mould?

jwalker · 06 December 2006, 17:24

Quote:

Originally Posted by Jizm

I was thinking of flowcoating the inside of the aluminium plate, glassing up the inside, then removing the plate?

Jiz, give the ally a coat of release wax and your method will work fine. I made 8x4 sheets of laminate by laying them up on an ally sheet. I only waxed it the first time, after that there was no need.

The only thing which occurs to me is the slight leakage down between the plate and the side of your consol. Rub a smear of plasticene into any wee gap that might be there.

Jizm · 06 December 2006, 17:41

Cheers JW.
Will covering the ally in clingfilm do any good,? rumour I heard.

jyasaki · 06 December 2006, 18:21

Personally, I'd find a panel that fit into the hole reasonably closely, and patch that into place. Lot less glassing, I'd think.

jky

Jono · 06 December 2006, 18:28

Quote:

Originally Posted by jwalker

Jiz, give the ally a coat of release wax and your method will work fine. I made 8x4 sheets of laminate by laying them up on an ally sheet.

I've got a 5 metre by 1 1/2 metre mould for flat sheets.. or at least I will have soon, won't I Gav?...

Anyone want to buy it..?

John Kennett · 06 December 2006, 18:57

Quote:

Originally Posted by Jono

I've got a 5 metre by 1 1/2 metre mould for slightly wonky sheets..

Fixed for you

John

Jono · 06 December 2006, 18:59

Now, now Oh Lanky One.... I'm in a good mood for a change... don't you go and spoil it.........

John Kennett · 06 December 2006, 19:07

Quote:

Originally Posted by Jono

I'm in a good mood for a change...

OK. Who are you? How did you get Jono's log on details?

John

Mollers · 06 December 2006, 20:39

Try Downbelowdai, he is highly experienced in dealing with such matters.

Endeavour · 06 December 2006, 21:41

trim the hole neat so you have good clean edges. then sand the inside so it tapers to nothing (or nearly) from about 10mm. use the ally (or melamine) but give a coat wax first. then screw it on from the outside with screws that are just long enough (or grind off excess). gelcoat the area from the inside on the temp mould. when gel has gone off, apply csm and resin using a larger piece for each layer. following day, unscrew temp mould, countersink screw holes and fill with gelcoat.

jobs a goodun

steve

jwalker · 06 December 2006, 21:53

Quote:

Originally Posted by Jizm

Cheers JW.
Will covering the ally in clingfilm do any good,? rumour I heard.

Nah, just use a wee polish of release wax.

Downhilldai · 06 December 2006, 22:03

Quote:

Originally Posted by Mollers

Try Downbelowdai, he is highly experienced in dealing with such matters.

No need. Endeavour's advice is spot on.

Mollers · 06 December 2006, 22:14

Quote:

Originally Posted by Downhilldai

No need. Endeavour's advice is spot on.

Eh? I'd have used a very different approach myself, beginning with a handful of spit.

Hugh Jardon · 06 December 2006, 22:17

Quote:

Originally Posted by Mollers

Eh? I'd have used a very different approach myself, beginning with a handful of spit.

is that because they are not usually wet enough already?