1986 550 hull seperation bond rail splitting

[Myself]

Last year my swapped '86 550 hull started taking on water. I found the rail splitting from the rear corners up to about the front of the tray. Apparently, this is a relatively common issue on the '86 hull. Here you can plainly see the seperation.

 

[Myself]

I figured if I could get some epoxy in there it would be an easy fix. First I slipped in these small pry bars and slid them back and forth making sure anything loose would be 'open'.

 

[Myself]

I sanded the edge of a paint paddle and cut it up making these little wedges. Then I just shoved them in about every 8 inches.

 

[Myself]

Next I doubled over a piece of 60 grit to get inside and sand a bit. The oem greenish glue sanded out easily.

 

[Myself]

I mixed up some epoxy with Cabosil thickener and added a bit of green pigment.....mostly to make it easier to see so I didn't miss anything.

 

[Myself]

Then I just started shoving , and working it into the open gap. Once that was filled in I removed one wooden wedge at a time and used the tongue depresser to slide some epoxy up in those spots too.

 

[Myself]

Then add some clamps and let it cure out........done!

 

[Big Kahuna]

Gonna ask stupid queation. Did you flip hull over?

 

[Myself]

I did not. With the thickened epoxy and the split opened up, you can push/mash the epoxy right up in there. I smeared it up in there first with the tongue depresser. Then with a gloved finger just push it in like your packing a bearing with grease.

 

[Myself]

FYI.......I rode this thing hard, several times times this summer.......all still good!