Columbia Coronado 25 Owenrs Manual Download

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TABLE OF CONTENTS

SECTION

INTRODUCTION

SECTION

BILL OF MATERIAL - DEFINED AND EXPLAINED

2.1

Fiberglass

2.2

Resins & Catalysts

2.3

Gelcoat

2.4

Marine Wood Products

2.5

Fasteners

2.6

Suppliers and Vendor List

SECTION

TECHNIQUES

3.1

Gelcoat Touch-up and Repair

3.2

Micro Balloon Filled Resin

3.3

Bonding

3.4

Cutting, Drilling, and Grinding

3.5

Winterization

3.6

Anti-fouling Protective Coating

SECTION

BLUEPRINTS AND DRAWINGS

SECTION

INSTALLATION OF COMPONENT KITS

5.1

General Assembly Instructions

5.1.1

Tools Required

5.1.2

Keelingand Leveling Hull

5.1.3

Temporary Cover Over Work Area

5.1.4

Importance of Leveling

5.1.5

Order of Assembly

Summary of Contents for Coronado 25

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Page 2: ...HNIQUES 3 1 Gelcoat Touch up and Repair 3 2 Micro Balloon Filled Resin 3 3 Bonding 3 4 Cutting Drilling and Grinding 3 5 Winterization 3 6 Anti fouling Protective Coating SECTION 4 BLUEPRINTS AND DRAWINGS SECTION 5 INSTALLATION OF COMPONENT KITS 5 1 General Assembly Instructions 5 1 1 Tools Required 5 1 2 Keelingand Leveling Hull 5 1 3 Temporary Cover Over Work Area 5 1 4 Importance of Leveling 5 ...

Page 3: ...5 7 Rudder Assembly 5 8 Keeling Procedure 5 9 Plumbing and Water Tanks 5 10 Stove and Tank Installation 5 11 Windows 5 12 Deck Hardware 5 13 Exterior wood 5 14 Electrical System 5 15 Cabinetry and Interior Wood 5 16 Spars and Rigging 5 17 Launching and Commissioning SECTION 6 FIBERGLASS REPAIR 6 1 Introduction to Fiberglass 6 2 Surface Repairs 6 3 Fracture and Puncture Repairs 6 4 Finishing Techni...

Page 4: ...ese sections should be read first as they will help you to understand what is being said in the Installation Section Section 4 deals with blueprints drawings and data concerning the assembling of your Sailcrafter Yacht This section will be used in conjunction with Section 5 The language used in the Manual has been simplified for your understanding Many terms have been defined and explained as they...

Page 5: ...ation for cloth refers to the approximate weight per square yard 7 1 2 oz cloth for example c WOVEN ROVING is used for structural purposes in conjunction with mat This is the material that provides maximum strength and rigidness to a fiberglass laminate Without woven roving a laminate of fiber glass cloth and mat would bend and flex Woven roving like mat is designated in approximate weight per squ...

Page 6: ...coat is pure resin catalyzed and with the appropriate color pigment added The gel coat finish on your Sailcrafter Yacht is very hard and needs no maintenance except for light waxing now and then to retain the luster of the color Unlike the construction resins mentioned earlier gel coat does not harden in the presence of air It is necessary to cover the gel coat with a soluble mold release coat or ...

Page 7: ... thru bolted with round or oval head bolts as appropriate Use the largest size bolt that will fit through the holes in the hardware Toe rails cabin trim and other decorative wood can be fastened with self tapping stainless steel screws These should be long enough to protrude through the fiber glass to the beginning of the full sized threads and then snapped off flush They should be countersunk and...

Page 8: ...eet Toledo Ohio Local marine hardware BEDDING COMPOUND PRC 80AT LIFE 65 Bloomingdale Rd Hicksville N Y Local marine hardware BILGE PUMPS PETERS RUSSEL Springfield Ohio Balboa Marine Hardware Newport Beach Ca BODY PUTTY POLYESTER Automotive paint stores Body shop BOTTOM PAINT INTERNATIONAL SAINT CO 21 West Street New York N Y WOOLSEY BRAND PAINT STORE BALBOA MARINE Newport Beach Calif CUSHIONS JOHA...

Page 9: ...each Blvd Norfolk Va GEL COATS RAM CHEMICAL 210 E Alondra Gardena Ca LENOIR COATINGS RESIN Lenoir North Carolina BEADS WILCOX CRITTENDEN Middleton Conn HEADS SELF CONTAINED MONOGRAM INDUSTRIES 6357 Arizona Circle Los Angeles Ca 9Q045 HEADLINERS JOHANSEN CHRISTENSEN 898 W 16th Street Costa Mesa Ca COLUMBIA YACHT CORP Portsmouth Virginia HOSE DUCTALL INDUSTRIAL HOSE RUBBER 2816 E 11th Street Los Ang...

Page 10: ...akersfield Calif LIGHTS INTERIOR FIXTURES Local marine hardware LO VOLT 2364 E 128 th Compton Calif LIGHTS RUNNING SWING AWAY Wesley Street Portsmouth Va Local marine hardware LIGHTS NAVIGATING Perkins Marine Miami Florida LUMBER TEAK Brush Lumber 7653 Telegraph Montebello Calif HOUSE OF HARDWOOD W Los Angeles Calif SPAR LUMBER 1325 Harbor Long Beach Calif DEAN HARDWOODS 3701 Elm Portsmouth Va ...

Page 11: ...ardt Santa Fe Springs Ca U S PLYWOOD Ingleside Rd Norfolk Virginia MEK CATALYST HARDENER LENOIR COATINGS RESIN Lenoir North Carolina ERSKINE JOHNS 4677 Worth Los Angeles Calif Local marine hardware MICRO BALLOONS Crystalliner 1626 Placentia Costa Mesa Calif LENOIR COATINGS RESIN Lenoir North Carolina MUFFLER SALISBURY RUBBER 401 No Morgan Chicago Illinois PAINT VARNISH INTERNATIONAL PAINT CO 508 N...

Page 12: ...Mesa Calif PULPITS Bow Stern RULE INDUSTRIES Cape Anne Industrial Park Glouscester Mass HARRIS MARINE 1308 Logan Costa Mesa Calif BALBOA MARINE HARDWARE Newport Beach Calif RELEASE P V C CRYSTALINER 1626 Placentia Costa Mesa Ca LENOIR COATINGS RESIN Lenoir N C ANKLE BELLEY Exhaust Flex ALLIED METAL HOSE CO Coupling 3746 Ninth Street Long Island City N Y SABER SAW BLADES PLETZ BROS Industrial Park ...

Page 13: ...ris 11341 San Fernando Rd San Fernando Ca Local marine hardware STOVES ALCOHOL BUTANE GALLEY MAID P O B 10417 Riviera Beach Fla KENYON MARINE GUILFORD CONN Local marine hardware TANKS FUEL TECSTAR INC 16550 N W loth Miami Fla Vic Berry 2527 W Coast Hwy Newport Beach Ca THRU HULL FITTINGS BRASS R C MARINE 17422 Armstrong Santa Ana Calif GEM MARINE Lake City South Carolina WILCOX CRITTENDEN Middleto...

Page 14: ...iviera Beach Fla Local marine hardware WATER PRESSURE PUMP PETERS RUSSELL Springfield Ohio Local marine hardware WINDOW GASKET vinyl foam tape PELTZ BROS black 3 16 thick x 5 8 wide Norfolk Va in 30 rolls 3M Bear 576 Industrial supply house WIRE PRIMARY DEL CITY WIRE CO P O B 82457 Oklahoma City Oklahoma STANDARD WIRE CABLE 3440 Overland Los Angeles Calif Local automotive supply Local electrical s...

Page 15: ... set faster Curing is slower at temperatures below 70 and does not proceed satisfactorily below about 57 Temperatures between 700 and 57 may be partially compensated for by slightly more catalyst High humidity also interferes with curing After the gel coat is sprayed on a thin layer of mold release 5006 mold release liquid from Thalco Corp should be applied with the spray gun to shut out the air a...

Page 16: ...and cure slowly or quickly depending on its application For example in large areas such as the keel rudder hull and deck fast curing is not required and slow curing will avoid distortion 4 The mixture should appear and be about the consistency of a thin pancake batter 5 Other areas where micro balloon filled resin is employed should contain more catalyst and more asbestos to form a thicker compoun...

Page 17: ... bonds should consist of 3 oz mat plus one layer of 7 1 2 oz cloth f No more than 2 catalyst by volume should be used in the resin mixture Excellent material used in boat construction that will bond well are marine plywood exterior plywood most hardwoods and hardened plywoods Solid teak is an exception as it is a very oily wood which is incompatible with the resin To bond teak plywood the teak out...

Page 18: ...as not to inhale powdered fiberglass Likewise power tools should be blown free of fiberglass dust since it is an abrasive in bearings motors and gears NOTE Caution should be used at all times when working with power tools on fiberglass The fiberglass is a very hard material and tools have a habit of slipping sliding and jumping out of place 3 5 Winterization For all boats with inboard engines and ...

Page 19: ...ouncil Surface Preparation Specification 5 b All sand and dust residue is to be removed from the surface before coating is applied c The ground surface must be primed before re rusting occurs For outdoor locations this normally means that the steel should be primed within a period not exceeding six hours after cleaning For indoors low humidity locations longer periods may be used The steel should ...

Page 20: ... before top coating 5 Anti Fouling Coating a Apply one 1 coat of Tri Lux T B T O antifouling to all of the keel and hull b Before applying the Tri Lux anti fouling to the hull the polyester gel coat should be thoroughly sanded to provide an anchor pattern or tooth for good adhesion c Allow four 4 hours drying time d Apply second coat of Tri Lux anti fouling as specified in Section 5 a e Allow 24 h...

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Page 46: ...y the above all over again until you are sure the interior suits your needs When this is done plan all assembly methods necessary for assembling the interior For example the main structural bulkhead to the mast post or the formica galley top joint to the galley face should be designed to conceal unfinished edges Be sure you have it all planned so that no unpleasant surprises will occur later The f...

Page 47: ...AW COUNTERSINKING DRILL BITS TABLE SAW NUMBER DRILL SET SABRE SAW TAP SET NATIONAL COARSE ELECTRIC HAND DRILL ACCURATE CARPENTER LEVEL RATCHET TYPE SCREW DRIVER CHALK LINE SMALL MITRE BOX 12 ROLL UP TAPE MITRE HAND SAW CARPENTER S HAMMER HACK SAW SET OF SCREW DRIVERS SET OF FILES SET OF WOOD CHISELS SET OF HOLE SAWS SOCKET AND OPEN END WRENCH SET 5 1 2 Keeling and Leveling Hull It is suggested tha...

Page 48: ... 1 3 Temporary Cover Over Work Area It is recommended that a temporary cover be built over the area in which you will be working The roof should be strong enough to protect your work area from snow and rain and if you are working in a colder climate it is suggested that inexpensive plastic sheeting be used to construct a windbreak all the way around the structure Be sure that the roof is high enou...

Page 49: ...l thru hulls at the same time is a good idea It is extremely important for the safety of your yacht that all thru hull glass work be done very carefully in accordance with Section 5 5 Once the interior is complete the next step should be to install all deck hardware and deck wood in accordance with the drawings Be sure that all hardware and wood is carefully through bolted and very carefully seale...

Page 50: ...hen riveting place rivets 3 apart When double lowers are used the rivet spacing shall be 1 1 2 from two feet forward of the forward lower to two feet aft of the aft lower Clean the H metal within two hours and seal rivet heads The open corners at the transom and the bow between the H metal shall be bonded with 4 oz of mat and one layer of 3 oz cloth After installing corner and bow castings a fille...

Page 51: ...r in bottom of H metal Use a wedge to run along top Rubber will fall into place Install corner and bow casting with machine screw in kit Then seal around castings and H metal top and bottom with marine sealer G E White to insure no leans Excess sealer should be cleaned before it cures RIVETING The rivet spacing should be 3 apart When double lowers are used the rivets should be 1 to 1 1 2 apart 2 f...

Page 52: ... are provided cut into 6 lengths and force up into the micro balloons until the bottom of the strips are just above the bottom of the joint In most areas you can cut some cleat stock 1 x 1 pine and using the shelf space or cabinet tops of the hull liner as an anchor base force the mahogany strips in tight Before the micro balloons go off scrape all the excess from the joint with a putty knife Cont...

Page 53: ...ntal and vertical pressure so that the shaft turns freely The stuffing gland should be at least 2 aft of the engine flange in order that the packing gland can be opened for the installation of packing The prop shaft tube should then be bonded in accordance with CSP 00 9054 Then fair out the bonds by sanding Fill the small voids with body putty sand gelcoat wet sand and buff For other Sailcrafter Y...

Page 54: ... The exhaust system consists of a stainless steel flex hose a water jacketed exhaust pipe a length of exhaust hose a pipe loop muffler which is a stock unit and a thru hull fitting The exhaust system location is shown in the hull assembly drawing The engine compartment ventilators are located in accordance with the deck assembly drawing The exhaust is a forced air system with the fan mounted on th...

Page 55: ...ll the void around it with random matting and resin Item 5 as shown 4 Bond over this filling with a cover bond Item 1 according to Section 5A of CSP 00 9031 1 lam 24 oz roving and 3 oz mat 5 Finish the installation by sealing the thru hull and tightening nut Item 3 6 If the thru hull device is of a flush mounting type use a bond equal to the outer hull laminate to secure it in place prior to filli...

Page 56: ...g to fit chainplate Place chainplate through deck and secure Seal around chainplate below and above deck Use Minnesota Manufacturing Company Weather Ban Sealant Tape 3 wide and 1 8 thick Slit and place over chainplate and secure chainplate cover Trim excess sealant with knife ...

Page 57: ...ot exceed 1 2 to 1 by weight 3 The tube is bonded to the hull with three 3 layers of 3 oz mat and three 3 layers of 24 oz woven roving Catalyst content of resin not to exceed 2 by weight Apply in three applications of one layer of mat and one layer of woven roving This laminate must extend at least 5 out from tube and 5 up onto tube 4 The top of the tube should terminate approximately 2 from the u...

Page 58: ... place Nylatron washer between hull and rudder Push rudder up Secure deck flange and place Nylatron washer under tiller head Install hex head set screw lining up rudder and tiller Drill through tiller head and rudder shaft and install hex head bolt and secure ...

Page 59: ... the hull measure from the aft tip of the keel to the bottom of the boot top on either side These two dimensions should be equal within 1 2 If these two dimensions are more than 1 2 shims shall be used made of stainless steel strip running the full length of the keel This shim must be completely encased in the Epibond 150AB when the keel is fitted to the hull 5 8 4 Remove keel from keel pocket and...

Page 60: ...king life Be sure to fill the gap between the hull pocket and the keel and clean all excess Epibond 150 A B within three hours The boat should not be put in the water before the 72 hour cure has been completed 5 8 10 The Epibond 150 A B should be sanded smooth and fair to blend the hull and the keel and repainted with Intergard 4424 4423 Primer over any spots where the sanding has cut through to t...

Page 61: ...e laminate particularly in the corners which will lead to leaks 4 The lid prior to installation shall be fitted with the required fill fitting The fill shall be thru bolted to the lid and sealed both sides with silicone sealant NOTE If a vent line or over flow line is not required by the plumbing drawing a 1 8 diameter hole will be drilled in the fill cap The fill shall be so located in the tank l...

Page 62: ...rine heads are shipped with the fittings loose Tighten all fittings on head Following the plumbing diagram place the pick up hose to intake on head and secure with stainless steel hose clamps Be sure to apply Pemetex to fitting before clamping Place exhaust hose to flash on head Run hoses to thru hull fittings Place head on base and bolt secure Fill head with water Close gate valve and pump head O...

Page 63: ...dition it is extremely important that the LPG tank and stove installation be carefully done and tested 2 The stove must be securely mounted on its gimbals in such a manner that it can swing freely 300 from vertical Stainless steel cotter pins must be installed to retain the stove in the gimbals 3 Remote supply tank or tanks must be installed in the fiberglass self draining sealed box in accordance...

Page 64: ...m period of five hours 6 For final inspection the following test should be made a Air pressure shall be applied to 10 psi with the tank valve open and all stove valves closed b If there is no measurable drop in pressure in a one hour period the system shall be considered acceptable 7 If at any time during any of the tests described in this procedure a leak is detected the source of the leak shall ...

Page 65: ...s whatsoever should be made 5 After the assembly of the stove and tank are completed perform the following tests a Close the valve on the tank Pump air pressure to 10 psi and observe the pressure gauge for possible tank leaks b If no leaks are observed in test a above then with all valves on the stove closed the valve on the tank shall be opened and the pressure drop noted after five 5 minutes Thi...

Page 66: ...en and all stove valves closed 2 If there is no measurable drop in pressure in a one hour period the system shall be considered acceptable 6 If at any time during any of the tests described a leak is detected the source of the leak shall be found and corrected and the test shall be started over again ...

Page 67: ...tic When all the templates are taped in place sc around them Remove the templates and make th outs along the scribe lines 2 Place bond between liner and deck to insure sole fit using 3 oz of mat and clamp until resin c 3 Sand gelcoat off inside and outside for 1 2 all way around the hole 4 Use a polyurethane sealant liberally under the frame and to the inside of the window frame Install wine Tight...

Page 68: ...late on the centerline of the deck The centerline of the upper hole in the backstay must be 3 above the deck and on the proper angle in line with the backstay to the top of the mast so that there is a straight pull on the plate Mount all other hardware in accordance with the deck assembly drawing Be sure to use either back up plates or a large flat washer under all hardware The genoa track is bolt...

Page 69: ...n deck Measure half the fore and aft outside measurement of the mast and add this to the J Drill a 1 4 hole at this point on deck and drop a plumb bob down to the bilge Mark the point in the bilge at the point of contact with the plumb bob This will be the center of the mast step Center the mast step on this point and rotate it to either port or starboard to align it with the centerline Then faste...

Page 70: ...the side rail caps Some trimming out at the underside maybe needed so ii will set down flush This can be accomplished by laying the bow cap it is in two pieces in line with the rail cap and scribing the underside Use a sharp chisel to remove the wood to the scribe line When the complete rail cap has been temporarily fastened down lay a thin batten along the outboard edge of the rail cap so that th...

Page 71: ...est This last mounts with the bottom flush with the bottom of the side coamings and will keep the water from running into the cockpit The helmsman s seat is also pre fit It mounts up under the side coamings and the backrest in the hack Screw from under the seat into the coamings and backrest There are four knees provided to give the helmsman seat added support in the 5 50 only Two are spaced evenl...

Page 72: ...ve at least one stainless steel thru bolt at each end fastening them to the deck Hand rails with more than two grips shall be fastened with thru bolts as illustrated below The intermediate grips shall be fastened with stainless steel selftapping screws The eyebrow trim is pre cut and shaped to fit the cabin top Follow the scribe line on the cabin to install this After installing them some shaping ...

Page 73: ...o route all cable bundles up out of the bilge so bilge water cannot get to them For connections to bilge pumps and other bilge mounted electrical devices the connection should be well up out of the bilge The mast wires come through the mast step and are secured to a female plug A male plug is wired in the same manner to the mast wiring so the mast can be disconnected easily when unstepped Secure w...

Page 74: ...c After installing the bulkheads the lockers may be installed screwing the locker shelf down to the ledge of the hull liner provided On all bulkheads and lockers that join the headliner toe in your screws through the top of the wood to the deck These need not be plugged as yen will be installing the teak trim over them and against the headliner The dish locker front and other lockers may be instal...

Page 75: ...set in place for bonding by screwing a cleat on the fore and aft bulkheads then setting the shelf on these and screwing it down from the top Leave all sea rail and pin rail to be installed last to keep from scratching or gouging them All bunks should have sea rail installed on the inboard edges to keep the cushions from sliding off The same applies to the dinette seats The sets or drawers and door...

Page 76: ...u screw it into the mast in a quality grease which also assists in reducing electrolysis All winches should be mounted on appropriately shaped teak blocks to both give proper support and separate them from the aluminum mast If winches are mounted on a flat surface of a mast it should also be separated by a non metallic material to reduce the possibility of corrosion Be sure that cotter pins are pl...

Page 77: ...t direction With a light pull or push by hand at chest height this dockside starting point will have both stays of equal tension with about 1 to 2 of play in the uppers and 2 to 3 of play in the lowers The backstay and jib stay should be of equal tension and have about 1 of play If the mast is stepped on deck the rigging will be tighter than a mast stepped on the keel With double lowers the after ...

Page 78: ...conculsion of the race it is very important to slack off the amount you took up on the backstay turnbuckle as this avoids setting up unnecessary strains on the hull and rig Since you want to keep the mast straight while racing you will probably tighten up on the jib stay first so when the backstay is slacked off the mast head will hook slightly forward When the backstay is tightened up this hook w...

Page 79: ...00 square foot Genoa Since the above load could easily be transmitted to one spot at any given time ALL of the Genoa Gear has been designed and prepared to accept those extreme loads The track is thru bolted and all blocks are oversize All other fittings are of the best possible design and strength FOR THE JOB INTENDED Most fitting failures occur from improper usage usually by trying to use a ligh...

Page 80: ...ts that have their mainsheet on the end of the boom there may be a roller reefing mechanism contained in the gooseneck fitting An optional GEARED ROLLER REEFING GOOSENECK may be installed in which a handle cranks the boom around and the sail is rolled down around the boom With mid boom sheeting most people will use the optional Cringle Reef System which is well illustrated and explained by drawing...

Page 81: ...rical properties Glass fibers normally have a sizing coating applied during their manufacture There are various types of sizings but all have some common purposes 1 to bind mono filaments together into a more easily handled fiber called a strand 2 to lubricate monofilaments so that they do not abrade and break each other and thus cause reduced strand strength and 3 to promote surface contact betwe...

Page 82: ...mold and the polymerization is called gellation or simply a cure Two ingredients are essential to the successful polymerization of a polyester resin a catalyst and a promoter A catalyst is a material that by its presence aids a chemical reaction without actually taking part in the reaction itself In the classic case a catalyst could be removed from the products of a chemical reaction and used agai...

Page 83: ...ly if at all and attempts to use it will result in a prolonged waste of time and labor To lengthen the pot life of catalyzed polyester resin fiber glass workers recommend the following practices 1 Mix only small quantities of resin and catalyst at a time 2 Avoid high ambient surrounding air temperatures 3 Keep containers cool such as by placing them in ice water Here are some suggested safety prec...

Page 84: ...the breaking force of the end product but only up to a point After that point has been reached the breaking force remains about the same but the strength pounds per square inch actually decreases For glass fiber polyester resin laminates however the percentage of glass fibers is usually limited by other factors such as economics and workability For instance manufacturers of fiber glass boats make ...

Page 85: ...It is cleaned thoroughly cracks and flaws are repaired and a release agent such as a wax is applied The proper gel coat is then brushed or sprayed onto those mold surfaces corresponding to the external surfaces of the finished part After the gel coat has cured enough glass fiber laminates for the desired thickness of the product axe cut to fit the mold and the resin is prepared with catalysts and ...

Page 86: ...ed for repairing all six types of surface damage covered in this manual are given below TOOLS Heavy duty polisher Harsh grit buffing compound Huffing pad for polisher Acetone White cloth Water Sanding block Gelcoat Putty knife Cab o sil collodial silica Cellophane Catalyst Single edge razor blade Milled fibers Rubber squeegee Sandpaper 100 220 400 600 grit H Preparing the Surface Fox restoring glo...

Page 87: ...nal putty S With the razor blade and before the gel coat cures scrape off the excess gel coat that you removed from the patched area in Step 4 above 6 Allow the putty to become firm and hard to the touch Then remove the cellophane D Sanding the Patch 1 Block sand the patch with 220 grit sandpaper to remove the excess putty and to restore the area to its original shape 2 If tiny pin holes appear in...

Page 88: ...her and apply harsh grit buffing compound to the pad 2 Holding the polishes at a 95 degree angle buff the patched area with just enough pressure to remove remaining scratches sandpaper grit etc 3 Restore the gloss to the area by holding the polisher flat and applying only light pressure F Spraying the Patch 1 If you have sanded through the gel coat or other surface finish that is fiber glass is vi...

Page 89: ...tep 1 as necessary to remove all debris C Huffing the Surface 1 Attach buffing pad to a heavy duty polisher and apply harsh grit buffing compound to the pad 2 Holding the polisher at a 95 degree angle buff the unit with just enough pressure to remove grease grit and grime CAUTION APPLY MINIMUM PRESSURE TO CORNERS AND EDGES SO AS NOT TO REMOVE THE GEL COATING 3 Holding the polisher flat on the surf...

Page 90: ... that you can stop sanding immediately when the scratch has been removed If you are not careful you might sand all the way through the gel coat and thus have to replace it D Sanding Buffing and Spraying 1 Wet sand the repaired area as instructed in Section 6 2 Procedure E Steps 4 and 5 2 Buff the repaired area as instructed in Section 6 2 Procedure F 3 If the gel coat has been sanded through durin...

Page 91: ...nd a matching gel coat Mix thoroughly until all lumps have been removed IMPORTANT If all lumps are not removed from the putty they will trap air that in turn will leave tiny pin holes in the area being patched The lumps also will appear as white spots in the patched area 2 Add catalyst to the putty in accordance with the manufacturer s instructions Mix thoroughly so that no uncured spots will occu...

Page 92: ...th acetone C Preparing the Patch 1 Make a thick creamy manageable putty by mixing equal amounts of milled fibers and a matching gel coat 2 Add catalyst to the putty in accordance with the manufacturer s instructions and mix thoroughly D Patching the Nicks and Small Holes See Section 6 2 Procedure D Steps 2 thru 6 E Sanding the Patch See Section 6 2 Procedure E F Buffing the Patch See Section 6 2 P...

Page 93: ...dentations in the gel coat surrounding the craze If ripples and indentations do appear after the craze has been removed go to Procedure C below 3 If after you have completed sanding the surface the craze appears in the fiber glass below the gel coat to to Section 6 3 Fracture Puncture Repairs 9 If after you have completed sanding the surface there are no ripples or indentations and the craze does ...

Page 94: ...r 6 3 Procedure E 5 Buff the patched area as instructed in Section 6 3 Procedure F 6 Spray finish the area with a matching color as instructed in Procedure D below and in Section 6 9 D Spraying the Repaired Area NOTE This procedure applies only when all necessary repairs to the crazed area have been completed that is the area has been sanded any craze extending as a fracture into the fiber glass h...

Page 95: ...l trap air that in turn will leave tiny pin holes in the area being patched The lumps also will appear as white spots in the patched area 2 Add catalyst to the putty in accordance with the manufacturer s instructions Mix thoroughly so that no uncured spots will occur in the patched area D Applying the Patch 1 Apply the putty smoothly over the damaged area with a rubber squeegee 2 Cover the area wi...

Page 96: ...Section 6 3 4 Punctures are classified as 1 holes that can be reached from both inside and outside the structure 6 3 5 or only from the outside of the structure 6 3 6 and 2 holes that are larger than 1 4 inch 6 3 7 TOOLS MATERIALS Power sander Fiber glass mat 24 grit sanding disc Fiber glass cloth Sanding block Resin Rubber squeegee Catalyst Putty knife Sandpaper 50 100 grit Scissors Gel coat Stir...

Page 97: ... mat IMPORTANT Fiber glass mat will not maintain its thickness when wet out with resin That is why it is so important to press the pieces of dry mat firmly into the area with your hands to insure a sufficient build up 3 Cut a piece of fiber glass cloth that completely overlaps the built up patch about one inch D Wetting Out the Patch 1 Mix resin and catalyst thoroughly with a stirring stick to pre...

Page 98: ...roperly NOTE Besides restoring the approximate original shape to the area the squeegee removes the remaining air bubbles in the patch Also the cloth makes squeegeeing possible It is impossible to squeegee directly on wetted mat IMPORTANT Take extreme care to remove as little of the resin as possible from the patch If too much resin is removed with the squeegee the patch will be resin poor that is ...

Page 99: ... a rubber squeegee 4 Apply the putty smoothly over the patch with the squeegee to fill all the tiny pin holes Hold the squeegee at a 45 degree angle and fill in any minor indentations in the fiber glass patch with the gel coat putty S Allow the putty to cure 6 Remove the excess putty and properly contour the area by block sanding with 100 grit sandpaper 7 Spray finish the area with matching gel co...

Page 100: ...ard White cloth Acetone Cellophane Woven roving B Repairing Outside of Structure when a compound fiber glass fracture is accessible from both outside and inside the structure begin on the inside Repair the fracture as instructed in Section 6 3 Procedures C through G IMPORTANT Omit Step 3 cleaning patch with acetone of Procedure G in Section 6 3 for now Also when removing damaged fiber glass with t...

Page 101: ...on all sides Section 6 3 Procedure D Step 3 3 Continue the repair as instructed in Section 6 3 Procedure G Steps 1 and 2 sanding the patch D Finishing the Outside and Inside Surfaces 1 Clean the outside and inside patched areas thoroughly with a white cloth saturated with acetone 2 Apply gel coat putty to the outside and the inside patched areas as instructed in Section 6 3 Procedure N 3 Spray fin...

Page 102: ...st Putty knife Sandpaper 50 100 grit scissors Gelcoat Stirring stick Cab o sil Paintbrush Cardboard White cloth Acetone Cellophane Woven Roving Masking Tape NOTE A puncture is a hole that goes all the way through the fiber glass structure being repaired When the hole is accessible from both outside and inside the structure repair it as instructed in this chapter beginning on the outside Procedure ...

Page 103: ...NT Omit Step 3 cleaning patch with acetone of Procedure G in Section 6 3 for now C Repairing Inside of Structure 1 Remove the piece of cardboard and cellophane from inside of the structure 2 with the power sander and 24 grit sanding disc remove enough of the fiber glass from the area so that at least two pieces of fiber glass patching material can be applied Following the general instructions of S...

Page 104: ...cloth sanding block Resin Rubber Squeegee Catalyst Putty knife Sandpaper 50 100 grit Scissors Gel coat Stirring stick Cab o sil white cloth Acetone Wire Milled fibers Stick Cellophane B Removing Damaged Fiber Glass 1 Remove the damaged fiber glass from the area as instructed in Section 6 3 Procedure C NOTE If the hole is small and roughly contoured shape it with the sander so that a piece of cardb...

Page 105: ...it conforms to the hole Then insert it through the hole again to determine whether it is flush against the hole IMPORTANT The cardboard must be removed from the hole and reshaped as many times as necessary until it conforms perfectly This procedure is necessary for the area to be restored to its original structural soundness 5 When the cardboard has been properly shaped remove it from the hole 6 R...

Page 106: ...the stick 17 Cut off the ends of the wire as soon as possible to the patch 18 Remove the remaining visible ends of the wire with the power sander D Sealing the Backup Patch 1 Mix resin and milled fibers in equal proportions 2 Add catalyst to the mixture in accordance with the manufacturer s instructions 3 With a putty knife apply the catalyzed mixture around the corners where the backup patch come...

Page 107: ...eegee Catalyst Putty knife Sandpaper 50 100 grit Scissors Cardboard Stirring stick Acetone Paintbrush Woven roving White cloth Masking tape Cellophane Milled fibers B Sanding the Hole 1 With the heavy duty sander and 24 grit sanding disc sand all sides of the hole outward at least 2 inches 2 Cup out the sanded area smoothly so that at least two layers of fiber glass mat can be applied later C Appl...

Page 108: ...ucture Continue the repair from outside the structure by building up the remaining area of the hole with pieces of fiber glass mat as instructed in Section 6 3 Procedures D through G E Finishing the Outside Surface Complete the repair from the outside by finishing the surface as instructed in Section 6 3 Procedure H F Patching the Inside of the Structure 1 Inside the structure remove the cardboard...

Page 109: ... piece of mat with the catalyzed resin 6 Apply the piece of mat over the hole Remove air bubbles with the paintbrush and your index finger NOTE Now that the hole has been filled with a mixture of catalyzed resin and milled fibers the fiber glass mat has been applied over the interior and exterior of the hole the area has been restored to its original structural soundness IMPORTANT Because the repa...

Page 110: ...e type of fiber glass visible on the inside of the structure see Section 6 3 Procedure C Step 2 9 Patch the area as instructed in Section 6 3 Procedures D through G 5 Complete the repair by finishing the surface as instructed in Section 6 3 Procedure H IMPORTANT spray finishing the surface is necessary when the repaired area can be seen from inside the structure such as a boat or shower stall ...

Page 111: ... wet Acetone 6 dry sandpaper Polyvinyl alcohol PVA Masking tape Buffing compound Sanding block Water Paper Stirring sticks Buffing pad heavy duty polisher B Preparing the Surface 1 Prepare the surface as instructed in Section 6 2 1 2 After the area has been thoroughly sanded and feathered apply masking tape Where possible place the tape on a sharp break or contour adjacent to the area This techniq...

Page 112: ...ust pattern control and trigger to regulate pattern The two should be balanced The smaller area to be sprayed the more the pattern and trigger nozzles should be closed D Applying Gel Coat 1 Position surface and or lights so that you can see the spray pattern as it forms on the surface 2 Spray gel coat on the area Spray uniformly to avoid producing light and heavy areas Apply 10 to 15 mils of gel c...

Page 113: ...ith a good quality epoxy enamel Manufacturers of epoxy enamels supply application instructions on the labels of the cans and in published booklets The manufacturer s instructions should be followed since different types require different solvents and or handling The following is a typical epoxy enamel finishing system which can be used as a guide TOOLS MATERIAL Suction spray gun or Sanding surface...

Page 114: ...ing It is important that you do not over thin the enamel and that you use the specified thinner 3 If you are going to spray the enamel test the spray pattern on a piece of cardboard and adjust pattern control and trigger to regulate pattern D Applying the Epoxy Enamel 1 Position surface and or lights so that you can see the spray pattern as it forms on the surface If you use a brush be sure it is ...

Page 115: ...nd patch scratches scars and small breaks 3 Repair any major breaks as soon as possible to avoid additional damage to the structure The outside surface of a fiber glass structure is usually formed by a colored gel coat This is a special resin material containing concentrated color It produces a smooth finished surface that will give many years of service when these simple maintenance steps are fol...

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