Repairing holes, painting and now Section 2 Complete!

Aside from the bulkhead repair and the cockpit sole repair, the other major repairs in the section I am working on (engine room, cockpit area) were to fill in many holes.  I glassed in some holes at the waterline that will either be moved or not used anymore: the refrigeration heat exchange water thru-hull, and a hole used for the engine exhaust water vent loop.  As mentioned previously, I filled in the cockpit area deck drain holes to modify their position.  I also had a few holes to fill in the cockpit itself, including the large hole where the old autopilot control was, an old hole used for a telephone jack, and the hold hole where the autopilot control/engage cable went through. Some of the holes required full build-up glassing, others (in the cockpit) required replacing the area with new core and glassing in.  This job was a big pain as a lot of grinding, glassing and sanding was required.  But as they were finally finished, I was able to paint necessary areas and give the rest a final cleaning to be done with this section.

With the engine room, cockpit area & quarter berth complete, I will now move to the front of the boat and work my way back.  I wanted to get the first two sections done because they were somewhat more complex than any of the other sections, with more involved projects that I wanted to get out of the way.  I will now work my way backwards so that as I clean the bilge areas, the gunk will flow down-hill.

Updated list for this section:

Deck: -Remove all deck hardware – COMPLETE -Pot thru-deck holes with epoxy – COMPLETE -Thoroughly clean with soap, then solvent – COMPLETE -Sand with 150 grit – COMPLETE -Fill/repair all unused holes – autopilot, old telephone plug, etc. – COMPLETE -Grind/bevel all dings and imperfections (including deck joint) – COMPLETE -Fair decks with thickened epoxy – COMPLETE -Sand fairing compound down to a smooth surface – COMPLETE -Re-Apply fairing compound and sand down as needed – COMPLETE

Hull sides & Transom: -Remove all hardware, thru-hulls & equipment – COMPLETE -Glass in old drain holes – COMPLETE -Thoroughly clean with soap, solvent, then On/Off where needed – COMPLETE -Wet sand gelcoat with 600 grit – COMPLETE -Sand cove stripe with 220 grit – COMPLETE -Repair any dings in gelcoat – COMPLETE

Engine Room: -Remove all hardware, wiring, plumbing, thru-hulls etc. – COMPLETE -Wash all surfaces – COMPLETE -Pressure wash bilge – Waiting to finish up-hill bilges -Repair cockpit sole from underside – COMPLETE -Glass in unused thru-hulls – COMPLETE -Rough sand all surfaces – COMPLETE -Clean sanded surfaces with solvent – COMPLETE -Paint ceiling with BilgeKote – COMPLETE -Sand gel-coat surfaces up to 600 grit - COMPLETE -Varnish Trim - COMPLETE -Add sound/engine room insulation (this will wait for later)

Quarter-Berth -Thoroughly clean all surfaces with soap & water (pressure wash lockers), then solvent - COMPLETE -Paint lockers with Bilgekote - COMPLETE -Sand gelcoat surfaces to 600 grit - COMPLETE -Varnish trim - COMPLETE

Without further ado, here are the pix...

Cockpit holes pre-work.  On the left is the auto-pilot clutch control, on the right is the auto-pilot control unit.

Ground out a bevel, ready for new core and glass:

Control unit hole cut to fit in new core:

New core in, glassed in:

Glassed in, final fairing from the outside:

More cockpit holes:

Core cut and filled with epoxy:

Waterline holes:

Glassed in:

Cockpit drain holes:

Cockpit sole, post repair, pre-paint

Post paint:

Engine room - mostly equipped

Post engine removal:


After first cleaning, pre-sanding:

After final cleaning, paint, and sanding:

Quarter berth, post clean, paint, sanding, and varnish: