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...
Closed Captions (CC):
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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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