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Faizan
Extending a fiberglass-constructed boat involves a major project and skill level because it requires the builder to essentially cut into and partially destroy the original hull of the boat. To be sure that the modified boat hull won’t leak at the seams, the new extension must be molded with the existing hull to create a new, unified hull and structure. This requires breaking the old end of the boat down to its core and essentially rebuilding it.
Remove and any all equipment attached to the end of the boat that will be extended, including the outboard engine and propeller assembly. Use scrapers and basic garage tools to remove any attachments and surface coverings adhered to the old boat end.
Plan out with pen and paper how the boat end will be extended. Base the extension measurements on the original boat design and structure. Keep the modifications within scope of the general boat shape and design; i.e., don’t build a new aft section three times wider than the original boat body.
Have a boat designer look over your work if possible to point out necessary corrections or issues you may have overlooked.
Cut into the old boat fiberglass of the section to be extended with a grinder or saws-all tool. Strip out and remove all of the old internal and external fiberglass. Cut out and pry the pieces until you are left with just the bare hull frame.
Put on a face mask to protect your lungs. Sand and grind the remaining surface of nearby fiberglass hull not be removed so the new layer will have something to bond with when joined with the old material.
Remove the old hull frame wood and beams if they cannot be reused. Prime the new marine plywood and wood beams completely with epoxy liquid so that the fiberglass can adhere to the new parts when applied.
Fill in and repair the frame with the extended design by adding framing and plywood as necessary to create the new, modified frame. Apply putty into gaps where holes or cracks exist. Continue patching until you have a complete, continuous hull surface of plywood or putty seams.
Put on plastic gloves. Mix fiberglass resin and hardener in a bucket with a mixing stick. Paint fiberglass resin on the wood beams and plywood surface one section at a time.
Fiberglass Application
Cut sections of fiberglass cloth with scissors. Begin to add fiberglass cloth, rolling and pressing the cloth into the first layer of resin as you work. Continue the first layer until a section is finished.
Paint more resin over the first cloth layer and apply a second cloth layer. Continue this process until at least three or four layers are applied. Cover the last layer with more resin. Continue section by section until the boat is surfaced with fiberglass that now adheres to the old fiberglass where the initial cut was made.
Allow the first layer to harden and cure. Go back and apply additional layers of cloth and resin the next day until your hull and internal surface of the boat are covered with enough fiberglass to meet your design needs.
Allow the second layer of fiberglass to dry and harden. Spread out your layers so they overlap old fiberglass surfaces. Avoid any clear seams or breaks from old to new fiberglass; these will lead to immediate cracks.
Drill out your necessary holes and cavities in the new hull for your engine equipment, pumps and propeller if it applies. Use a power drill and boring bits to make the holes. Seal the edges of these holes so that when the equipment is installed the contact with the hull is water-tight.
Begin sanding and grinding the surface area and edges of the new fiberglass. Smooth out all edges and trim so that the finished fiberglass transitions to the old fiberglass without delineation.
Apply epoxy on any dips, gaps or holes. Paint the final hull-surface with waterproof boat hull paint and a roller brush.
Remove and any all equipment attached to the end of the boat that will be extended, including the outboard engine and propeller assembly. Use scrapers and basic garage tools to remove any attachments and surface coverings adhered to the old boat end.
Plan out with pen and paper how the boat end will be extended. Base the extension measurements on the original boat design and structure. Keep the modifications within scope of the general boat shape and design; i.e., don’t build a new aft section three times wider than the original boat body.
Have a boat designer look over your work if possible to point out necessary corrections or issues you may have overlooked.
Cut into the old boat fiberglass of the section to be extended with a grinder or saws-all tool. Strip out and remove all of the old internal and external fiberglass. Cut out and pry the pieces until you are left with just the bare hull frame.
Put on a face mask to protect your lungs. Sand and grind the remaining surface of nearby fiberglass hull not be removed so the new layer will have something to bond with when joined with the old material.
Remove the old hull frame wood and beams if they cannot be reused. Prime the new marine plywood and wood beams completely with epoxy liquid so that the fiberglass can adhere to the new parts when applied.
Fill in and repair the frame with the extended design by adding framing and plywood as necessary to create the new, modified frame. Apply putty into gaps where holes or cracks exist. Continue patching until you have a complete, continuous hull surface of plywood or putty seams.
Put on plastic gloves. Mix fiberglass resin and hardener in a bucket with a mixing stick. Paint fiberglass resin on the wood beams and plywood surface one section at a time.
Fiberglass Application
Cut sections of fiberglass cloth with scissors. Begin to add fiberglass cloth, rolling and pressing the cloth into the first layer of resin as you work. Continue the first layer until a section is finished.
Paint more resin over the first cloth layer and apply a second cloth layer. Continue this process until at least three or four layers are applied. Cover the last layer with more resin. Continue section by section until the boat is surfaced with fiberglass that now adheres to the old fiberglass where the initial cut was made.
Allow the first layer to harden and cure. Go back and apply additional layers of cloth and resin the next day until your hull and internal surface of the boat are covered with enough fiberglass to meet your design needs.
Allow the second layer of fiberglass to dry and harden. Spread out your layers so they overlap old fiberglass surfaces. Avoid any clear seams or breaks from old to new fiberglass; these will lead to immediate cracks.
Drill out your necessary holes and cavities in the new hull for your engine equipment, pumps and propeller if it applies. Use a power drill and boring bits to make the holes. Seal the edges of these holes so that when the equipment is installed the contact with the hull is water-tight.
Begin sanding and grinding the surface area and edges of the new fiberglass. Smooth out all edges and trim so that the finished fiberglass transitions to the old fiberglass without delineation.
Apply epoxy on any dips, gaps or holes. Paint the final hull-surface with waterproof boat hull paint and a roller brush.
Posted in: boating
