In this week's episode of Onboard Lifestyle we remove fourteen decades old thru-hull fittings on our custom 435 catamaran SV basik. This project that was lon...

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welcome back to sv Vesak you know we're

getting into a group now I've been

glassing all morning this is the sixth

or seventh layer on this just laid this

one down look at this starting to

flatten this out feeling good about the

strength here

Lynn's been sanding for hours every day

I know she's getting fed up I think we

need to shift gears for a day or two

give her a break from sanding and attack

these we have 16 of these to eliminate

we're gonna shape these out and glass

over them there's so many because we've

shifted all the cabins and interior

utilities all around the heads have

changed the galleys have changed

everything's changed we've Moon moves

builds pumps so we need to get rid of

these shave them out of there and now's

the time I don't want 16 extra through

holes on the boat so here's Lynn

sanding away four hours a day

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get pretty close I think we're probably

at the 90 percent 85 90 percent

these are some of the through holes

we're gonna be taking out and there are

scattered throughout the boat

I think she'll be happy to shift gears

Hey won't take a break maybe try

something else besides sanding you're

getting else you get tired of sanding it

yes but look at those guns you're

getting all when you're ready okay let's

do through-holes

I think it'd be fun kind of give us a

change of pace for a day or two start

shaving these out 16 of them 16 some

days I've already filled but I need to

grind these out and gloss over him these

were just done in the field so you ready

to hit it

let's see those guns yellow good they

are

you did good look at this I think we're

uh we're getting there okay let's hit

these your holes

okay over the years I've added all of

these stainless new through holes and

I've shaved some out these are gonna be

classed over I need to grind those out

we're gonna be removing all these so

we'll start with just get all of them

removed I'm sure some of these are gonna

come out easy

I have Mian Tilton actually feel loose

some may be a little more difficult we

have to cut him out I'm not sure yet

we'll just kind of dive into this and

try to get all these three holes removed

first let's see it we're in for a great

thing is we're not sanding Emma and

you're gonna help us get all those

little holes out okay okay we have 16 to

do your dad's gonna be outside and we're

gonna be in here pulling him through so

we need the channel locks are you ready

yeah okay okay

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okay I need the hammer and the

screwdriver let's do the next one okay

okay go ahead and start tapping the

second one there you go

okay Linz already busted these free okay

go ahead push him out oh and the other

one that's a little tighter can you get

that one

there you go okay two more kiss number

five this one's actually a tough one to

get to it's it's way behind the

daggerboard daggerboard trunk runs right

up through here and lend us a stuff

herself behind her to read says hey are

you in there can you reach it okay oh

there you go

number five that was easy okay look at

this

everything's run real smooth surprised

how easy these are all coming out and

not one of them ever leaked but they're

just popping out like butter

and tell this one this one's below the

waterline I can see that it's 5200 on

here it's the all intake for the Baba

stove heating and air conditioning are

you in there there should be water in

this one open the seacock

that's what I thought that's it

now we'll try to get this one out this

one should be pretty tough

so we hit our leg and we're gonna have

to cut this one out

[Applause]

look at all that

yeah

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alright let's just leave this one just

kitchen

[Applause]

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well that went actually pretty smooth

mostly it's just popped right out even

these ones below the waterline look at

this this one looks like it was an

original through-hole for when the boat

was made 26 years ago because there was

no paint around it and it's dry as can

be in here take a look at these sheer

holes I'm so glad I took these out some

of these just were brittle I mean we

just went to turn them and look at this

just snapped in half we had a couple of

them like that just just pieces the most

part though actually where was this one

right here below the waterline it's been

painted so many times look at that

barely see through it and this was just

on finger tight Oh glad to get this mess

off the boat

okay good morning new day we've taken

out 14 to the 16 through holes I'm

leaving to for the last and I'm gonna

prep these holes to pop them look at

this the hole is just under an inch

thick but we are out a honeycomb

composite it's a poly propylene core

this is 90 core so we can't do the

typical patch job you would on a

fiberglass boat and I'll show you why

okay when you're repairing traditional

fiberglass boat and you drill a hole

through it there's you through hole now

I want to repair the hole this is a

cross-section you grind back the

exterior surface and then you make

laminations

to fill the hole makes a nice solid

repair but with nynuk or here's a

cross-section of night decor you have

all this honeycomb this is all air

filled so if you grind this back you're

just exposing this core cell material so

what I do

let's look straight down on the work

here here's the through-hole I put a

patch in here of the same core now the

honeycomb looks like this if you look at

it around the hole and on the patch

just the opposite so as I inject thick

and epoxy around this perimeter here it

fills this whole void and locks this

plugin creates a spline makes it

impossible to pop it out after that's

done you could grind back all the

surface coating and lay new glass cloth

on here on both sides works out pretty

slick I'll show you how I did it

okay over the years as I cut holes in

the boat or through holes all my little

cord plugs here and I have a various

amount of sizes thicknesses depending on

where they came from the boat and I

saved these for a reason

this is for doing the repairs later you

know I may not have all the right sizes

here but I could cut other plugs out of

these and you know for the most part you

could grab one of these plugs and epoxy

it right in place Scheib the surface

here so when I grind this back it planes

out that way when I do my glass

laminations on here it gets plenty of

bite on the hole and the repaired

surface and I'll do that on both sides

okay before I put my plug in I have

removed just one quarter inch 3/8 inch

of this polypropylene core from the

perimeter of this that way when I pack

this with thick and epoxy has a nice

overlap I'll do the same thing with the

hole you see I've already started

dishing this out here I'll make sure

this is all nice and clean I'll put a

nice layer of thick in the PAC's in here

a nice layer on this perimeter then I'll

flush this out and let it cure

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we are working on our last hole teal has

been plugging in all up and I have been

mixing epoxy as we go cleaning behind

him are you thinking I'm thinking I'm

getting tired of these Oh

one day one day you're tired of it just

so many okay okay so I'm packing in this

thickened epoxy making sure I get it all

the way into that core make sure have

enough okay now I need to pack this I

pack the core here as well

it's like frosting a cake yes it is

speaking of cake sounds kind of good

there you go you done now I go to the

inside do the same thing okay I feel

good 14 of these holes have been filled

today we'll let these fire off and cure

overnight and I'll grind those back in

the morning and start getting glass on

nations on both the outside and inside

of the hole who's talked to more through

holes through back here they're in a

tight location inside the engine

compartment I'll tackle those a little

bit later but we did good today I feel

good about this

so I'll get cleaned up off to the

showers and it's movie night

so we'll kick back I know Emma's been

looking forward to it all day so should

be fun

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and good morning

well the epoxy cured overnight so I got

up this morning and ground down every

patch we put in down to the bare NightA

core went pretty smooth yes ground them

out enough that I could put at least two

layers on the exterior then I'll be able

to fare over that and Prime and paint

I'll be putting at least two to three

layers on the interiors of all these you

know I got looking at this I thought wow

look at all these through holes you know

we've just shaved out 14 I've got nine

left they're all above the waterline

I don't have one through-hole right now

below the waterline the intakes for the

engines coming through the sail dries I

will be putting one through-hole right

right Indian rope I read back here and

that's gonna handle seawater for both

heads and supply the water maker so I

got to thinkin is that a lot to a nine

exterior through holes above the water

and one below you know I think that's

pretty good I walked over next door to

this leopard 46

and I counted his through-holes 42

through holes in this pug 18 of them are

below the water so I think we're doing

pretty good

okay

let's get back over here start laying

some glass okay the girls are prepping

the glass for me lens cutting 28 circles

I know you're doing good

Emma's taking all the scraps if she

busted apart you can always have a

bucket a chopped strand going tell me

why I waste this right now yeah hey you

guys doing good

okay you got all this holes cut I guess

you did not holes anymore your patches

their patches yeah they're all done

we're just waiting for you okay just

wetting out the surface and then I could

start putting them in it's at the last

of it now this is easier are you

laughing it ain't putting down the first

layer here

okay this went pretty smooth today

actually all the through holes have been

patched we got two layers of eight ounce

cloth on everyone well let these fire

off tonight and these be cured enough

that I could prep these for a fare and

compound tomorrow if these sanded smooth

and these will be done can you think I'm

gonna call it for tonight Emma's been

itching to fly Carl our new drone I told

her she has to finish flight training

first so so she finishes will get Carl

up in the air I can't wait I'm I'm just

as excited as she is

three

you getting the hang of this yet yeah

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a lot of commotion in the yard this

morning

kids he's fired up overnight and I sent

it in smooth they're all prepped and

ready preparing compound

let's take a look at what I'm using

got anything all set up this is 3ms

Platinum filler I just like how this

lays down and it sands nice and easy so

I'll be using that today just hoping

this spray from this pressure wash

doesn't hit me it looks like it's just

missing me

let's start wearing this in

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so now that this is cured I'll knock it

down with an orbital so it's about maybe

a 64th proud than hand sander up

okay that project wasn't too bad over

the course of three days I probably

spent three three and a half hours a day

working on these through holes but

they're all done these are ready for

primer and paint boy I like how those

tonight I mean you can't even feel those

okay so another project to knock off the

list I think I'll call it see you guys

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