Directions—handling epoxy

Safety• Avoid skin contact with resin, hardener or mixed epoxy. Wear

protective clothing.

• Avoid eye contact with resin, hardener or mixed epoxy. Wearprotective glasses. In case of contact with eyes, flush with waterfor 15 minutes. If discomfort persists, seek medical attention.

• Avoid inhalation of vapors. Provide adequate ventilation. Wear adust mask when sanding epoxy, especially epoxy that has notfully cured.

• Do not allow a large quantity of mixed epoxy to cure in a mixingcontainer, or other confined space. A large contained mass ofcuring epoxy can give off hazardous vapors and generateenough heat to cause burns and melt plastic mixing pots.

• KEEP OUT OF THE REACH OF CHILDREN

Preparation• Check all parts for proper fit.

• Be sure all surfaces to be coated are clean, dry and sanded.

• Gather all necessary application tools, clamps and equipmentbefore mixing epoxy.

Mixing and curingEmpty the contents of one resin and one hardener packet into amixing cup. Mix thoroughly. Use the flat end of the mixing stick andscrape the sides and bottom of the mixing cup as you mix.Mixing the resin and hardener together starts a chemical reactionthat transforms the combined liquid ingredients into a solid. Aftermixing 105 Resin and 205 Fast Hardener, you will have 10–15 min-utes, at 70°F (21°C), to apply the mixture before it begins to gel.Epoxy cures faster in warmer temperatures and thicker applica-tions. When the mixture is spread-out in a thin layer, the heat is dis-sipated and the working time and cure time are extended. Epoxycures slower in cooler temperatures and thinner applications.The epoxy mixture will reach a workable cure in five to seven hoursat 70°F (21°C). Clamps can be removed and the epoxy may besanded, but it should not be subjected to high loads for 24 hours.When a quicker cure is desired, applying moderate heat will sub-stantially reduce cure time.Slower hardeners are available in standard sized containers forlarger jobs. They provide extended working time at normal temper-ature and useful working times at higher temperatures. For infor-mation visit the WEST SYSTEM website or contact West SystemInc.

CleanupClean uncured epoxy from skin and clothes with a waterless skincleaner, followed by washing with soap and water.Remove excess epoxy from work surfaces with the flat end of amixing stick or with paper towels. Cleanup residue with a solventsuch as acetone or lacquer thinner.

Basic techniques

BondingGlue most parts together in a two-step operation. First, wet-out

(pre-coat) bonding surfaces with unthickened epoxy to improveadhesion and help prevent an epoxy-starved joint, especially whenbonding porous surfaces. A pipe cleaner or syringe may be used towet out hard to reach areas such as fastener holes when bondinghardware.After bonding surfaces have been wet out, add 406 Filler to an ep-oxy mixture, thoroughly mixing in filler until it reaches the desiredconsistency—thick (non-sagging) for larger gaps and uneven mat-ing surfaces—thinner for tight joints or large smooth surfaces.Apply a generous amount of the thickened epoxy mixture to one ofthe surfaces and clamp the components in position before the ep-oxy begins to gel. Use just enough clamping pressure to squeeze asmall amount of thickened epoxy out of the joint. Allow the epoxy tocure thoroughly before removing clamps or stressing the joint.Use 406 Filler (a high-density filler) to thicken epoxy for structuralbonding and gap-filling. Use the syringe to inject unthickened tomoderately thickened epoxy into small cracks or holes.

Making filletsWhen parts are joined at or near right angles, fillets can be used toadd considerable strength to the joint by increasing the surfacearea of the bond. Shape the excess thickened epoxy that hassqueezed out of the joint into a cove section using the round end ofa mixing stick. Add more thickened epoxy as necessary to shape asmooth fillet of the desired size. Clean off the excess mixture withthe beveled end of the mixing stick.

Fairing (surface filling)Wet out the surface with unthickened epoxy to improve adhesion.Stir 407 Filler into an epoxy mixture until it reaches the consistencyof stiff peanut butter. Use the mixing stick to apply and shape themixture slightly higher than the desired surface contour. Sand toshape after the epoxy cures. Seal the sanded fairing compoundwith unthickened epoxy before painting.Use 407 Filler (a low-density filler) to thicken epoxy for light bond-ing, and surface filling and shaping. The more 407 Filler you add tothe epoxy—the easier it will be to sand.

CoatingApply the epoxy mixture as a coating using a disposable brush.Brush the epoxy over the area and finish with long, light strokes toevenly distribute the epoxy over the surface. Add a small amount of406 Filler to create a thicker coating. Keep in mind that the thickerthe coating—the less smooth it will be.

More information

For larger wooden and fiberglass boat repair projects WESTSYSTEM offers comprehensive repair publications and a DVD,loaded with reliable, up-to-date repair information.

002-550 Fiberglass Boat Repair and MaintenanceA complete, illustrated guide to repairing fiberglass boats withWEST SYSTEM Epoxy. Includes detailed instructions on repairingcore damage, keel damage and structural reinforcing. Also coversfairing keels, hardware bonding, finishing and installing teak ve-neers. Softcover—76 pages. $4.25 (US)

002-650 Gelcoat Blisters: Diagnosis, Repair & PreventionThis manual provides a thorough explanation of osmotic blistering,and detailed, illustrated instructions on effective laminate dryingtechniques, repairing localized and severe interlaminate blisterdamage, techniques for applying an effective epoxy barrier coatand more. Softcover—52 pages. $4.25 (US)

002-898 WEST SYSTEM Epoxy How-To DVDFiberglass boat repair techniques are demonstrated in this instruc-tional DVD. Learn how to repair cored and non-cored hulls anddecks, and how to repair and prevent gelcoat blisters. The interac-tive menus also take you through Basic Application Techniques,everything you need to know about the use of WEST SYSTEM Ep-oxy, including epoxy safety and the fundamentals of coating, bond-ing and fairing. DVD—59 minutes. $18.00 (US)

002-970 Wooden Boat Restoration & RepairThis manual shows you how to do professional level repairs andrenovations that dramatically extend the life of your wooden boat.Dry rot repairs, structural frame repairs, and plank repairs usingmodern products and techniques are among the many solutionscovered in this fully illustrated manual. For boats that belong on thewater, not in museums. Softcover—80 pages. $4.25 (US)These WEST SYSTEM publications are available from your localWEST SYSTEM dealer, by call ing West System Inc. at866-937-8797 (toll free), or visiting our online InfoStore atwestsystem.info.

Free informationIf you don’t have a boat repair project, but want to know more aboutWEST SYSTEM Epoxy and what you can accomplish with it, visitwww.westsystem.com, or send for the WEST SYSTEM User Manual

& Product Guide.

002-950 WEST SYSTEM User Manual & Product GuideThis illustrated guide is essential for first time WEST SYSTEM Epoxyusers. It covers epoxy handling, safety and the basic techniquesused in most repair and building procedures. It includes completeproduct descriptions, selection and coverage information, and aproblem solving guide. Softcover—30 pages. FREEAsk for the FREE Literature Pack and you will receive the User Man-

ual & Product Guide, as well as 000-425 Other Uses—Suggestions

for Household Repair, the latest issue of Epoxyworks magazine, thecurrent product price list and the Stocking-Dealer Directory.Subscribe to Epoxyworks, a magazine about building, restorationand repair with epoxy. A subscription includes six FREE issues.Call 866-937-8797 or visit westsystem.info

Maxi Repair PackBRAND

®

Your reliable solutionWEST SYSTEM is the world’s leading brand of marine epoxy. It wascreated by Gougeon Brothers—sailors, boat builders and formula-tors who literally wrote the book on wood/epoxy boatbuilding. Assailboat and iceboat racing fueled their quest for lighter and stron-ger structures, it ultimately lead to a stronger, more versatile, andmore reliable epoxy.Over the past 40 years, reliability has been the hallmark of WESTSYSTEM Epoxy. We adhere to the highest standards of quality as-surance in our formulating and manufacturing practices, from rawmaterial qualification to testing and certification of finished resinsand hardeners. This means that properly mixed WEST SYSTEMresin and hardener will cure as it is supposed to, every time.When you need an extremely strong, water-resistant coating or ad-hesive, WEST SYSTEM epoxy is your reliable solution. This commit-ment to producing quality, reliable epoxy products has earned uscertification to the ISO 9001:2000 standard.

Backed by reliable technical adviceIf you have any questions or comments about the use of WESTSYSTEM products or would like to talk about the suitability of WESTSYSTEM Epoxy for a project, contact our helpful and knowledge-able West System Technical Staff. Call 866-937-8797 (toll free).

Because West System Inc. cannot control how this product will be used, it makes no warranties,either expressed or implied, including no warranties of merchantability and fitness for purpose in-tended. West System will not be liable for incidental or consequential damages.

WEST SYSTEM is a registered trademark of West System Inc., Bay City, MI 48707

When you mix WEST SYSTEM Resin and Hardener you create atough, waterproof coating that you can apply to nearly any surface.Use the mixture to apply fiberglass tape for reinforcing and abra-sion resistance. Add high-density fillerto make a strong, gap-filling adhesivethat bonds to wood, fiberglass, steeland aluminum. Add low-density fillerto create an easily sanded,non-shrinking surface filler.The repairs described inthese instructions are justthe beginning of what youcan do with the Maxi RepairPack. The resins, hardeners,fillers, fabric and applicationtools in this kit offer hun-dreds of repair, reinforcing,protecting and possibili-ties for wooden boats,fiberglass boats andmuch more.

Directions—handling epoxy

Safety• Avoid skin contact with resin, hardener or mixed epoxy. Wear

protective clothing.

• Avoid eye contact with resin, hardener or mixed epoxy. Wearprotective glasses. In case of contact with eyes, flush with waterfor 15 minutes. If discomfort persists, seek medical attention.

• Avoid inhalation of vapors. Provide adequate ventilation. Wear adust mask when sanding epoxy, especially epoxy that has notfully cured.

• Do not allow a large quantity of mixed epoxy to cure in a mixingcontainer, or other confined space. A large contained mass ofcuring epoxy can give off hazardous vapors and generateenough heat to cause burns and melt plastic mixing pots.

• KEEP OUT OF THE REACH OF CHILDREN

Preparation• Check all parts for proper fit.

• Be sure all surfaces to be coated are clean, dry and sanded.

• Gather all necessary application tools, clamps and equipmentbefore mixing epoxy.

Mixing and curingEmpty the contents of one resin and one hardener packet into amixing cup. Mix thoroughly. Use the flat end of the mixing stick andscrape the sides and bottom of the mixing cup as you mix.Mixing the resin and hardener together starts a chemical reactionthat transforms the combined liquid ingredients into a solid. Aftermixing 105 Resin and 205 Fast Hardener, you will have 10–15 min-utes, at 70°F (21°C), to apply the mixture before it begins to gel.Epoxy cures faster in warmer temperatures and thicker applica-tions. When the mixture is spread-out in a thin layer, the heat is dis-sipated and the working time and cure time are extended. Epoxycures slower in cooler temperatures and thinner applications.The epoxy mixture will reach a workable cure in five to seven hoursat 70°F (21°C). Clamps can be removed and the epoxy may besanded, but it should not be subjected to high loads for 24 hours.When a quicker cure is desired, applying moderate heat will sub-stantially reduce cure time.Slower hardeners are available in standard sized containers forlarger jobs. They provide extended working time at normal temper-ature and useful working times at higher temperatures. For infor-mation visit the WEST SYSTEM website or contact West SystemInc.

CleanupClean uncured epoxy from skin and clothes with a waterless skincleaner, followed by washing with soap and water.Remove excess epoxy from work surfaces with the flat end of amixing stick or with paper towels. Cleanup residue with a solventsuch as acetone or lacquer thinner.

Basic techniques

BondingGlue most parts together in a two-step operation. First, wet-out

(pre-coat) bonding surfaces with unthickened epoxy to improveadhesion and help prevent an epoxy-starved joint, especially whenbonding porous surfaces. A pipe cleaner or syringe may be used towet out hard to reach areas such as fastener holes when bondinghardware.After bonding surfaces have been wet out, add 406 Filler to an ep-oxy mixture, thoroughly mixing in filler until it reaches the desiredconsistency—thick (non-sagging) for larger gaps and uneven mat-ing surfaces—thinner for tight joints or large smooth surfaces.Apply a generous amount of the thickened epoxy mixture to one ofthe surfaces and clamp the components in position before the ep-oxy begins to gel. Use just enough clamping pressure to squeeze asmall amount of thickened epoxy out of the joint. Allow the epoxy tocure thoroughly before removing clamps or stressing the joint.Use 406 Filler (a high-density filler) to thicken epoxy for structuralbonding and gap-filling. Use the syringe to inject unthickened tomoderately thickened epoxy into small cracks or holes.

Making filletsWhen parts are joined at or near right angles, fillets can be used toadd considerable strength to the joint by increasing the surfacearea of the bond. Shape the excess thickened epoxy that hassqueezed out of the joint into a cove section using the round end ofa mixing stick. Add more thickened epoxy as necessary to shape asmooth fillet of the desired size. Clean off the excess mixture withthe beveled end of the mixing stick.

Fairing (surface filling)Wet out the surface with unthickened epoxy to improve adhesion.Stir 407 Filler into an epoxy mixture until it reaches the consistencyof stiff peanut butter. Use the mixing stick to apply and shape themixture slightly higher than the desired surface contour. Sand toshape after the epoxy cures. Seal the sanded fairing compoundwith unthickened epoxy before painting.Use 407 Filler (a low-density filler) to thicken epoxy for light bond-ing, and surface filling and shaping. The more 407 Filler you add tothe epoxy—the easier it will be to sand.

CoatingApply the epoxy mixture as a coating using a disposable brush.Brush the epoxy over the area and finish with long, light strokes toevenly distribute the epoxy over the surface. Add a small amount of406 Filler to create a thicker coating. Keep in mind that the thickerthe coating—the less smooth it will be.

More information

For larger wooden and fiberglass boat repair projects WESTSYSTEM offers comprehensive repair publications and a DVD,loaded with reliable, up-to-date repair information.

002-550 Fiberglass Boat Repair and MaintenanceA complete, illustrated guide to repairing fiberglass boats withWEST SYSTEM Epoxy. Includes detailed instructions on repairingcore damage, keel damage and structural reinforcing. Also coversfairing keels, hardware bonding, finishing and installing teak ve-neers. Softcover—76 pages. $4.25 (US)

002-650 Gelcoat Blisters: Diagnosis, Repair & PreventionThis manual provides a thorough explanation of osmotic blistering,and detailed, illustrated instructions on effective laminate dryingtechniques, repairing localized and severe interlaminate blisterdamage, techniques for applying an effective epoxy barrier coatand more. Softcover—52 pages. $4.25 (US)

002-898 WEST SYSTEM Epoxy How-To DVDFiberglass boat repair techniques are demonstrated in this instruc-tional DVD. Learn how to repair cored and non-cored hulls anddecks, and how to repair and prevent gelcoat blisters. The interac-tive menus also take you through Basic Application Techniques,everything you need to know about the use of WEST SYSTEM Ep-oxy, including epoxy safety and the fundamentals of coating, bond-ing and fairing. DVD—59 minutes. $18.00 (US)

002-970 Wooden Boat Restoration & RepairThis manual shows you how to do professional level repairs andrenovations that dramatically extend the life of your wooden boat.Dry rot repairs, structural frame repairs, and plank repairs usingmodern products and techniques are among the many solutionscovered in this fully illustrated manual. For boats that belong on thewater, not in museums. Softcover—80 pages. $4.25 (US)These WEST SYSTEM publications are available from your localWEST SYSTEM dealer, by call ing West System Inc. at866-937-8797 (toll free), or visiting our online InfoStore atwestsystem.info.

Free informationIf you don’t have a boat repair project, but want to know more aboutWEST SYSTEM Epoxy and what you can accomplish with it, visitwww.westsystem.com, or send for the WEST SYSTEM User Manual

& Product Guide.

002-950 WEST SYSTEM User Manual & Product GuideThis illustrated guide is essential for first time WEST SYSTEM Epoxyusers. It covers epoxy handling, safety and the basic techniquesused in most repair and building procedures. It includes completeproduct descriptions, selection and coverage information, and aproblem solving guide. Softcover—30 pages. FREEAsk for the FREE Literature Pack and you will receive the User Man-

ual & Product Guide, as well as 000-425 Other Uses—Suggestions

for Household Repair, the latest issue of Epoxyworks magazine, thecurrent product price list and the Stocking-Dealer Directory.Subscribe to Epoxyworks, a magazine about building, restorationand repair with epoxy. A subscription includes six FREE issues.Call 866-937-8797 or visit westsystem.info

Maxi Repair PackBRAND

®

Your reliable solutionWEST SYSTEM is the world’s leading brand of marine epoxy. It wascreated by Gougeon Brothers—sailors, boat builders and formula-tors who literally wrote the book on wood/epoxy boatbuilding. Assailboat and iceboat racing fueled their quest for lighter and stron-ger structures, it ultimately lead to a stronger, more versatile, andmore reliable epoxy.Over the past 40 years, reliability has been the hallmark of WESTSYSTEM Epoxy. We adhere to the highest standards of quality as-surance in our formulating and manufacturing practices, from rawmaterial qualification to testing and certification of finished resinsand hardeners. This means that properly mixed WEST SYSTEMresin and hardener will cure as it is supposed to, every time.When you need an extremely strong, water-resistant coating or ad-hesive, WEST SYSTEM epoxy is your reliable solution. This commit-ment to producing quality, reliable epoxy products has earned uscertification to the ISO 9001:2000 standard.

Backed by reliable technical adviceIf you have any questions or comments about the use of WESTSYSTEM products or would like to talk about the suitability of WESTSYSTEM Epoxy for a project, contact our helpful and knowledge-able West System Technical Staff. Call 866-937-8797 (toll free).

Because West System Inc. cannot control how this product will be used, it makes no warranties,either expressed or implied, including no warranties of merchantability and fitness for purpose in-tended. West System will not be liable for incidental or consequential damages.

WEST SYSTEM is a registered trademark of West System Inc., Bay City, MI 48707

When you mix WEST SYSTEM Resin and Hardener you create atough, waterproof coating that you can apply to nearly any surface.Use the mixture to apply fiberglass tape for reinforcing and abra-sion resistance. Add high-density fillerto make a strong, gap-filling adhesivethat bonds to wood, fiberglass, steeland aluminum. Add low-density fillerto create an easily sanded,non-shrinking surface filler.The repairs described inthese instructions are justthe beginning of what youcan do with the Maxi RepairPack. The resins, hardeners,fillers, fabric and applicationtools in this kit offer hun-dreds of repair, reinforcing,protecting and possibili-ties for wooden boats,fiberglass boats andmuch more.

1Plan access to the keel’s dam-aged area when the boat is

hauled.

2Dry the damaged area. Use aheat gun or fans to accelerate

drying.

3Remove any loose plastic filleror lead chips. Always wear a

dust mask, especially when work-ing around lead.

4Forge displaced lead to-ward voids using a ham-

mer. With a lead keel, a bulgeeach side of a dent is typical.Some lead may be saved.

5Coat the remaining bulgeswith petroleum jelly to improve

cutting performance, and plane orfile flush. After bulges have beenfaired, clean the area with a sol-vent. Allow the surface to drycompletely. Scrub the surfacewith a wire brush to expose freshlead.

6Brush epoxy into the re-maining voids. For maxi-

mum adhesion, immediatelyscrub the wet epoxy-coatedmetal surfaces with a wirebrush.

7Apply epoxy thickened to“peanut butter” consistency

with 407 (low-density) Filler to fillvoids. Allow the mixture to curethen sand fair. Repeat as neces-sary to achieve the desiredsmooth shape.

8Apply several coats of un-thickened epoxy over the re-

pair and allow to cure. Wetsand the final coat before ap-plying bottom paint. Follow thepaint manufacturer’s recom-mendation for final preparationand application.Epoxy also bonds well to cast ironkeels and can be used to shapeand fair both lead and cast ironkeels for optimum performance.For detailed information on fairingkeels refer to 002-740 Final Fair-ing & Finishing, published byWest System Inc.

Repairing damaged keelsMetal bonding and fairing

1Remove loose or damagedmaterial. Open cracks with a

sharp, “V”-shaped tool, scrapingdown to the bottom of the crack.Dry out the damaged area if nec-essary. Feather the edges with ascraping tool or 100-grit sandpa-per.

2Apply enough epoxy mixtureto thoroughly wet out the dam-

aged cavity.

3Blend 406 (high-density) Fillerwith the remaining epoxy mix-

ture to make a thick, non-saggingmixture. Trowel the mixture intothe pre-wet cavity.

4Allow to cure about 24 hours at70°F (21°C).

5Sand to shape before painting.Use 80-grit sandpaper to level

any ridges or bumps if necessary.Wet sand to fair with 220-grit pa-per. For high-gloss paints, con-t inue wet sanding down to400-grit or follow the paint manu-facturer’s recommendations for fi-nal preparation and application.Marine-grade paints or gelcoatprovide the ultraviolet protectionrequired for epoxy. Two-part poly-urethane paints provide the mostdurable long-term protection.

For deeper cracks

1Grind out the crack, until youreach solid laminate. Taper all

sides of the void to a shallow(about 12:1) slope.

2Cut multiple pieces of fabric tofit within and fill the void. Cut

each layer progressively smaller,with the largest, bottom layerabout ½" smaller on each edgethan the void.

3Wet out the fabric with epoxyusing a disposable brush. Ap-

ply largest piece in the center ofthe void. Apply the smaller piecescentered evenly over the largerpieces. Wet out the entire voidwith epoxy and allow to cure.Proceed to Step 3 above for fin-ishing when the epoxy begins togel, but is still tacky.Refer to the manuals and DVD onthe back of this sheet for more de-tailed information on repairingand finishing damaged fiberglass.

Repairing minor cracks and scrapeson fiberglass decks and hulls

Repairing delamination ofcore panels

Repairing loose hardwareInstalling new hardware

1Define the delaminated area.When pushed or stepped on,

delaminated skin feels flexible be-fore contact with the core and in-dicates a gap between the skinand core. Also, delaminated skinsounds flatter—less resonantthan solid laminate when tappedwith a coin or other small hard ob-ject.

2Dry the core thoroughly beforerebonding. Drill ¼" (6mm)

holes, 1" (2.5cm) apart and about3" (7.5cm) beyond the delami-nated area. Drill through the skinand about 1/3 of the way into thecore.Use a moderate heat source suchas a hot air gun or heat lamp to ac-celerate the drying process. Takecare not to damage the skin withexcessive heat. A sample drillingfrom the core will indicate the de-gree of dryness.

3Thicken an epoxy mixture with406 (high-density) Filler to a

“catsup” consistency. Load into asyringe. Trim the syringe tip asnecessary.

4Inject the thickened mixtureinto all holes drilled in the de-

laminated area. Flex the skin sev-eral times to work the epoxy intoall areas between the skin andcore.

5Place weights on the skin toforce it into contact with the

core until the epoxy cures. Placea plastic sheet under the weightsto prevent inadvertent bonding.

6Sand the surface fair with80-grit sandpaper after the ep-

oxy is completely cured. Fill anyremaining low spots with epoxyand 407 Filler thickened to a “pea-nut butter” consistency. Sandwhen cured and coat with unthick-ened epoxy.

7Wet sand when cured to pre-pare for painting or gelcoat.

Follow the paint manufacturer’srecommendation for final prepa-ration and application.For repair of large delaminated ar-eas, refer to Section 5 of 002-550Fiberglass Boat Repair & Mainte-nance.

1Remove the existing hard-ware. Protect the surrounding

area from spills.

2Clean dirt, old sealants andother materials from hard-

ware, deck surface and fastenerholes. Drill oversized holes to ex-pose uncontaminated deck mate-rial and increase bonding area. (Ifbacking plate and bolt are notused, drill the oversize hole only3/4 of the pilot hole depth.)Allow core material to dry thor-oughly. Use a heat gun to speeddrying.

3Place hardware in position.Trace the perimeter with a

pencil. Remove the hardware andtape the marked perimeter withelectrical tape.

4Sand the surface thoroughlyto a dull finish.

5Coat both the deck surfaceand the hardware mating sur-

face with the epoxy mixture. Wetout the inside of the fastener holewith an epoxy-wet pipe cleaner,or by injecting epoxy with a sy-ringe.

6Scrub all epoxy-wet hardwaresurfaces with 50-grit sandpa-

per before epoxy gels.

7Mix epoxy and 406 (high-den-sity) Filler to a “mayonnaise”

consistency. Apply generously tothe mating surfaces, in fastenerholes and on fastener threads.Use a syringe to fill holes, if nec-essary.Optional: coat fastener threadsand hardware base with pastewax if you anticipate removinghardware in the future.

8Position the hardware andtighten the fasteners until

some of the epoxy mixturesqueezes out. Do not overtighten.

9Clean excess epoxy awaywith a sharpened mixing stick.

Remove the electrical tape. Allowto cure for 24 hours at 70°F(21°C) before stressing.

1Plan access to the keel’s dam-aged area when the boat is

hauled.

2Dry the damaged area. Use aheat gun or fans to accelerate

drying.

3Remove any loose plastic filleror lead chips. Always wear a

dust mask, especially when work-ing around lead.

4Forge displaced lead to-ward voids using a ham-

mer. With a lead keel, a bulgeeach side of a dent is typical.Some lead may be saved.

5Coat the remaining bulgeswith petroleum jelly to improve

cutting performance, and plane orfile flush. After bulges have beenfaired, clean the area with a sol-vent. Allow the surface to drycompletely. Scrub the surfacewith a wire brush to expose freshlead.

6Brush epoxy into the re-maining voids. For maxi-

mum adhesion, immediatelyscrub the wet epoxy-coatedmetal surfaces with a wirebrush.

7Apply epoxy thickened to“peanut butter” consistency

with 407 (low-density) Filler to fillvoids. Allow the mixture to curethen sand fair. Repeat as neces-sary to achieve the desiredsmooth shape.

8Apply several coats of un-thickened epoxy over the re-

pair and allow to cure. Wetsand the final coat before ap-plying bottom paint. Follow thepaint manufacturer’s recom-mendation for final preparationand application.Epoxy also bonds well to cast ironkeels and can be used to shapeand fair both lead and cast ironkeels for optimum performance.For detailed information on fairingkeels refer to 002-740 Final Fair-ing & Finishing, published byWest System Inc.

Repairing damaged keelsMetal bonding and fairing

1Remove loose or damagedmaterial. Open cracks with a

sharp, “V”-shaped tool, scrapingdown to the bottom of the crack.Dry out the damaged area if nec-essary. Feather the edges with ascraping tool or 100-grit sandpa-per.

2Apply enough epoxy mixtureto thoroughly wet out the dam-

aged cavity.

3Blend 406 (high-density) Fillerwith the remaining epoxy mix-

ture to make a thick, non-saggingmixture. Trowel the mixture intothe pre-wet cavity.

4Allow to cure about 24 hours at70°F (21°C).

5Sand to shape before painting.Use 80-grit sandpaper to level

any ridges or bumps if necessary.Wet sand to fair with 220-grit pa-per. For high-gloss paints, con-t inue wet sanding down to400-grit or follow the paint manu-facturer’s recommendations for fi-nal preparation and application.Marine-grade paints or gelcoatprovide the ultraviolet protectionrequired for epoxy. Two-part poly-urethane paints provide the mostdurable long-term protection.

For deeper cracks

1Grind out the crack, until youreach solid laminate. Taper all

sides of the void to a shallow(about 12:1) slope.

2Cut multiple pieces of fabric tofit within and fill the void. Cut

each layer progressively smaller,with the largest, bottom layerabout ½" smaller on each edgethan the void.

3Wet out the fabric with epoxyusing a disposable brush. Ap-

ply largest piece in the center ofthe void. Apply the smaller piecescentered evenly over the largerpieces. Wet out the entire voidwith epoxy and allow to cure.Proceed to Step 3 above for fin-ishing when the epoxy begins togel, but is still tacky.Refer to the manuals and DVD onthe back of this sheet for more de-tailed information on repairingand finishing damaged fiberglass.

Repairing minor cracks and scrapeson fiberglass decks and hulls

Repairing delamination ofcore panels

Repairing loose hardwareInstalling new hardware

1Define the delaminated area.When pushed or stepped on,

delaminated skin feels flexible be-fore contact with the core and in-dicates a gap between the skinand core. Also, delaminated skinsounds flatter—less resonantthan solid laminate when tappedwith a coin or other small hard ob-ject.

2Dry the core thoroughly beforerebonding. Drill ¼" (6mm)

holes, 1" (2.5cm) apart and about3" (7.5cm) beyond the delami-nated area. Drill through the skinand about 1/3 of the way into thecore.Use a moderate heat source suchas a hot air gun or heat lamp to ac-celerate the drying process. Takecare not to damage the skin withexcessive heat. A sample drillingfrom the core will indicate the de-gree of dryness.

3Thicken an epoxy mixture with406 (high-density) Filler to a

“catsup” consistency. Load into asyringe. Trim the syringe tip asnecessary.

4Inject the thickened mixtureinto all holes drilled in the de-

laminated area. Flex the skin sev-eral times to work the epoxy intoall areas between the skin andcore.

5Place weights on the skin toforce it into contact with the

core until the epoxy cures. Placea plastic sheet under the weightsto prevent inadvertent bonding.

6Sand the surface fair with80-grit sandpaper after the ep-

oxy is completely cured. Fill anyremaining low spots with epoxyand 407 Filler thickened to a “pea-nut butter” consistency. Sandwhen cured and coat with unthick-ened epoxy.

7Wet sand when cured to pre-pare for painting or gelcoat.

Follow the paint manufacturer’srecommendation for final prepa-ration and application.For repair of large delaminated ar-eas, refer to Section 5 of 002-550Fiberglass Boat Repair & Mainte-nance.

1Remove the existing hard-ware. Protect the surrounding

area from spills.

2Clean dirt, old sealants andother materials from hard-

ware, deck surface and fastenerholes. Drill oversized holes to ex-pose uncontaminated deck mate-rial and increase bonding area. (Ifbacking plate and bolt are notused, drill the oversize hole only3/4 of the pilot hole depth.)Allow core material to dry thor-oughly. Use a heat gun to speeddrying.

3Place hardware in position.Trace the perimeter with a

pencil. Remove the hardware andtape the marked perimeter withelectrical tape.

4Sand the surface thoroughlyto a dull finish.

5Coat both the deck surfaceand the hardware mating sur-

face with the epoxy mixture. Wetout the inside of the fastener holewith an epoxy-wet pipe cleaner,or by injecting epoxy with a sy-ringe.

6Scrub all epoxy-wet hardwaresurfaces with 50-grit sandpa-

per before epoxy gels.

7Mix epoxy and 406 (high-den-sity) Filler to a “mayonnaise”

consistency. Apply generously tothe mating surfaces, in fastenerholes and on fastener threads.Use a syringe to fill holes, if nec-essary.Optional: coat fastener threadsand hardware base with pastewax if you anticipate removinghardware in the future.

8Position the hardware andtighten the fasteners until

some of the epoxy mixturesqueezes out. Do not overtighten.

9Clean excess epoxy awaywith a sharpened mixing stick.

Remove the electrical tape. Allowto cure for 24 hours at 70°F(21°C) before stressing.