[quote=DanBerger]Wow, that is turning into a major repair--but you can do it. I would go to West Marine and get some of their 2 part epoxy and some woven glass sheets. I would pick up some filler/bonding agent, too. I don't think you would need more than a quart of the epoxy. West sells pumps for the epoxy and hardener that give you the precise measurements and makes it very easy to get the ratio correct. You can always add a little more hardener to make it kick off faster.
There is a good article on fiberglass vacuum bagging work: http://www.westsystem.com/ss/assets/HowTo-Publications/Vacuum-Bagging-Techniques.pdf
I don't think you would need to vacuum bag, but there is a lot of good info on general fiberglass work in that pdf.
You are going to have to cut an access port in the deck in front of the beam to get to the back of the fix in front of the beam. I believe the deck piece is only to make the boat water tight, I don't think it is structural. If I'm wrong and it is structural--and you then wouldn't want to install an inspection port, you can pry the deck off by getting a sharp chisel under it and working your way around. When you are done, you can clean it up and use 3M 5300 to glue it back down. Someone check me on that--it might be 5200. I have found that an excellent bonding agent is that filler/bonder that West sells. I'll get you that item number tonight.
So, set yourself up with some glass sheets that you can glue in behind the cut out area. You will need one for the reinforcement running down the hull, one for the top including the cradle and one for the side of the hull. You will probably need more for the other inside places as well.
What you are doing is building a backing so you can build up glass on the outside. You can do most of it through the opening, but you will end up needing to get at the back of it once you have closed everything off.
See if you can make a mold of the curved surfaces and cover that mold with wax paper or saran wrap. lay down sheets of glass and add epoxy between layers. I'm thinking 3 layers would be sufficient. Then, sand the glass mold with 40-60 grit and sand the inside of the hull. Clean thoroughly with Acetone. Then, mix up a thick mixture of epoxy and that bonding stuff. use that as a glue to glue the mold to the inside of the hull. When it has cured, you can then start building up glass on the outside and make sure that you taper the glass on the hull around your cutout so that it has something to bind to. I would add one more layer of glass on the back of your backing plate (if you can get to it) to make sure that the edges will adhere to the inside of the hull.
You should do that for all the surfaces you need to build up.
I'm working on a similar issue, I'll be posting my progress. My issue is a crack in the hull, I don't have all the contours you do..
If you want help on it, you can drag it down to my house and we can get you started![/quote]
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