x2 hull repair question

I recently purchased a 1988 x2 and after looking a little closer I noticed some damage in the front. I have been doing a lot of reading on here and have a pretty good idea about how I should repair it. I know this is a smc hull so I have to use a polyester based resin. I plain on ordering everything from us composites. My questions are what type of fiberglass cloth should I use? What would be the best way to repair it? Should I cut the whole damaged area completely out then build it up with foam, shape it and then start laying up fiberglass? Are they any other weak spots I should reinforce? Thanks for all the help!
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Vumad

Super Hero, with a cape!
Location
St. Pete, FL
You should not use poly resin. You should use epoxy.

I prefer 3:1 laminating resin with 1208 bias because it's was what I started with and it has worked good.

That is a lot of damage and you should probably remove all of the damaged areas. But, before you start cutting, let me tell you how I would repair it.

I personally use a method I made up called on the part. You use the existing hull to make a mold of the damaged area several inches larger than the damage. The hen use this mood to repair the hull.

To make the mold, You can fill any damaged areas with a cheap product like drywall mud or spackle and finish it with cheap spray appliance epoxy. Wax the hull, pva optional it can be brushed on, then layup a few layers of glass. If using 1208 without a vacuum, 2-3 is fine and you can use poly resin for this if you have it on hand. Once the mood is cured, remove it from the hull.

Now cut out the damaged hull as you were planning to in the beginning. Save the waterbox straps of course. Once you have all the damaged removed, prep the inside of the hull by removing any ribs or other objects in the way, sand with 80 and clean with acetone.

Now you are ready for your repair. Wax your mold and reattach it by some means you prefer like tape or straps. The mold should be waxed but the hull should not. Layup your repair using the mold to shape the repair in place. If using 1208 you want to use 3-4 layers on the nose if not bagging. Use your mood thickness to gauge if you need more layers of glass in the repair. Let cure. Once the repair has cured, remove the mold and admire your work.

Complete any body work with epoxy mixed with a filler such as talc. Do not use microsperes are they will leave pin holes in your finish.

Reinstall your waterbox straps by installing hull inserts. You can use stainless steal tee barbed tee nuts but they are hard to find in metric. I would suggest you use Ufos from jetmaniac so you can keep with all metric hardware. Whatever you use, it must be stainless or brass.
 

Vumad

Super Hero, with a cape!
Location
St. Pete, FL
That is a really good idea! Ill have some thinking to do on how I wanna do it. Thanks for the help!

Here is a write up of the on the part method. Its not complicated but i realize pictures help.

http://www.x-h2o.com/index.php?threads/the-on-the-part-method.162922/

All of yojr steps are the same except,
1 you dpnt cut to reshape, you just fill cracks and holes to get the original shape back
2 you may nlt want to use gelcoat so ypu can reinforce from the outside when done (maybe lighter like 2 layers of 6oz
3 you should use filler and feather it in at the end since the repair is visable
 
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