Super Jet "Poly" Re-Foam/Hull Repair

[weston]

After a previose repair fialed I decided to cut an acces hole in the tray to get to the back side of the hole in the bottom deck After cuttting the hole I found a bunch of smelly water. At this point I knew this was going to be a complete defoam and I figured id better reinforced both chimes on either side of the pump tunnel and reinforce the rear bond rail as it was cracked. I used a few layers of 1710 biaxl and Evercoat SMC/Fiberglass resin.

 

[weston]

I decided to use ridges foam so the drains I would be installing would actually work. I shaped the foam using a hack saw for the straight cuts and a hack saw blade for rough shapping. I used 36 grit sandpaper for a better detail when sanding i finshed shapping/sanding with 80 grit. I used a piece of cardboard for a templet.

 

[weston]

After fitting the foam I started working on the drains. I put a 1/8" drill bit in a dremel to get the drain hole where I wanted it then used a stanless nylock nut for the drain. After roughing the nylock up with a grinder I used 3M panel bond to glue the nylock in place. 3m panel bond is the shiz the gun to use it isnt cheap but the stuff id bullet proof! a tube is about $40.00

 

[weston]

More shapping and fitting. The pump bolt inserts where not sealed from the inside so I used pnael bond to seal those as well as the cooling and stering lines to the hull. I also removed and put panel bond around the pump shoes screws.

 

[weston]

After glassing the bottom of the tray back together I did a final install of the foam. (after several test fits) layed down some panel dond and glued the tray in place.

 

[weston]

after the Glue setup (24hrs for full cure) I layed down one layer of 1710 biaxl to seal the seams up. I then drilled a few holes to pour the two part foam in. I added two part foem just to make sure everything was snug. after the foam kicked I layed 3 layers of 1710 bial over the intire tray. after that kicked I took the hull to the shop to make it shine.
once I get a chance Ill post a pictute of the bottom with clear coat on it.
I still need to install a foot strap, padding and turf.

 

[Sanoman]

One of the best pictorials l've seen on here! Thanks for sharing. Should be a sticky for newbs.

 

[MADMAT]

Nice write up!

 

[Jp79]

That is some attention to detail there! Nice job!

 

[WILKEY]

Very nice

 

[weston]

Thanks fellas.
I couldn't find a detailed thread on the subject so I figured I would make a step by step "how to thread" ill finish it off with details on foot strap, 1 1/4" pad and turf install