Thanks everyone for the posts on this topic. I just want to make sure I am 100% clear on this before starting any work.

1. Oversize the hole and install a tube of G10 rod which will then take the compression of the bolts as hardware is applied. http://www.mcmaster.com/#grade-g-10-garolite/=1253imd

2. Use Vinylester resin for all of the repairs .. do not use epoxy as it will shrink. If the holes in the deck are to be permanently filled, put fiberglass cloth over using the vinylester resin.

Have I missed anything here? Sorry for the repeat but want to ensure I do this once and not twice!!

Thanks, Don

:: Don,

:: You use a syringe and thicken the resin so it will not
:: flow out. It works well and worth buying a box of
:: syringes since they can be hard to reuse and are cheap.
::
:: I am sorry but epoxy does not shrink more the vinyl
:: ester resin. Poly and vinyl ester both have styrene and
:: vinyl has more, which keep the resin useable, then most
:: of the styrene evaporates (what you smell) and then it
:: shrinks by volume. It is different for each resin and
:: some high-end vinyl will be better if you add DMA. But
:: those are high elongation resins that most people will
:: not spend the money for to repair boats.
::
:: G-10 tube is a great idea and it really does not matter
:: if you go from top or bottom, the compression will be on
:: the tube. And if done properly it will not leak, this
:: adds a lot of time to filling holes but is the best
:: method. On boat builds when we go from bottom if deck is
:: still upside down, and if the deck is on the boat we go
:: from top. This is a critical thing to do with honeycomb
:: cores. As I said best practice, but not really needed
:: with balsa core.
::
:: One other point if you do use epoxy, which I would not
:: recommend, is to be aware of amine blush. This is a haze
:: that appears on the surface of cured epoxy. It needs to
:: be washed off with soap, water, and 3m pad. The flushed
:: with water, if not what ever you put on there will peal
:: off. There are some major boat builders who did not do
:: this and then, well, major structural problems.
::
:: Best of luck Don, and enjoy the process. These are our
:: babies.
::
::
:: :: Thanks everyone for the great input and suggestions.
:: :: This timely for me as well as I am filling holes as
:: :: well.
:: ::
:: :: My question is how do you inject the vinyl ester in from
:: :: the bottom? Easy to understand the tubes and placing in
:: :: the oversize hole but do you let it dry and then fill in
:: :: around or do you even fill it in? Is it possible for a
:: :: scanned hand sketch?
:: ::
:: :: Thanks!
:: ::
:: :: :: Well....I'm glad to see that another E-27 is in the same
:: :: :: boat as me!!! I also need to do a bunch of rebedding and
:: :: :: this info is very useful...
:: ::
:: :: :: A. I had no idea that epoxy shrinks...I thought only
:: :: :: Bondo shrunk and products that use a cream hardener...
:: ::
:: :: :: B. The G-10 also makes great sense for compression.
:: :: ::
:: :: :: My big problem is that I still need to figure out what
:: :: :: hardware is going back on :)
:: :: ::
:: :: ::
:: :: :: Thanks for sharing your trials and tribulations, etc. I
:: :: :: almost feel like I have joined some type of fraternity
:: :: :: here!!!
:: :: ::
:: :: :: Best Regards,
:: :: ::
:: :: :: Pete
:: :: ::
:: :: :: :: Hi all,
:: :: :: ::
:: :: :: :: I've removed all the hardware from my deck and am about
:: :: :: :: to over-drill, fill, and re-drill.
:: :: :: ::
:: :: :: :: I'm wondering if anybody has some good tips on how to
:: :: :: :: keep the expoxy from dripping through the holes and into
:: :: :: :: the interior.
:: :: :: ::
:: :: :: :: Taped on wax paper under the hole? Wait until epoxy is a
:: :: :: :: thick consistency? Use thickeners?
:: :: :: ::
:: :: :: :: I'd love to not have to learn this one the hard way ;-)
:: :: :: ::
:: :: :: :: Thanks
:: :: :: ::
:: :: :: :: Bryan