I inherited a cheap chopper gun Sears 17 footer.
It has multiple (amateurish) patches that need to be redone, along with a pretty major hole (~6") flanked by two linear cracks (2-3’ on each side towards the bow and stern) along the curve where the side meets the bottom. The multiple patches are scattered all over the canoe, including the bow and stern. The gel coat is scratched and gauged all over and one of the gunwales (aluminum) is slightly bent in at the center of the canoe.
I know, I know…I should trash the boat…but that would be too easy.
Planned process, would love comments from those of you with more experience in this area:
- Sand the entire canoe down until I reach the stranded fiberglass.
- Cut out all the minor repairs & sand inside around repairs
- Put some sort of backing on the outside of the minor repairs and lay them up with (6 oz E-Glass? Something heavier to make up the wall thickness more quickly?) from the inside
- On the outside, cover the large area of the major hole and the linear cracks with some sort of release agent, maybe just plastic sheeting.
- Create a mold by laying up a single layer of 6 oz E-Glass on top of the plastic. (I’m worried about retaining the curvature of the hull bc this repair is on the curve)
- Remove mold and plastic/release agent and cut out the major damage hole and the the linear cracks (I am imagining the hole will be shaped something like an airplane prop )
- Attach the mold created in Step #5 to the outside of the canoe with clamps, ect to provide backing
- Lay up the major repair from the inside (using the mold as a backing) with (6 oz E-Glass? 24 oz. Woven roving? Biaxial Mat 1708?)
- Cover the entire boat with one layer of 6 oz E-Glass (Not sure about this step - is this done is strips or something?)
- Sand, roll and tip finish.