installing thru deck fitting

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stx203

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Oct 15, 2009
58
Oday 25 Tall Rig Fin Keel Chesapeake - Middle River, Md
I am about to tackle putting a "waste" thru deck fitting for pumping out the holding tank on older ODAY 25. Previous owner would bring the pump out nozzle in thru the forward hatch and insert in a small length of hose from the holding tank.

I want to do the install the right way...do I cut a 2" hole in deck then dig out core an additional 1"...then fill with epoxy, let cure and then redrill the 2" hole plus three smaller holes for the fasteners through the deck......or do I drill out a complete 3" hole, totally fill it with epoxy then drill the larger hole and fastener holes in the hardened epoxy?

Should I be adding any strengthening agent to the epoxy?

All ideas appreciated.
 
sailingdog

sailingdog

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Oct 22, 2008
3,502
- Telstar 28 Buzzards Bay
stx203 said:
I am about to tackle putting a "waste" thru deck fitting for pumping out the holding tank on older ODAY 25. Previous owner would bring the pump out nozzle in thru the forward hatch and insert in a small length of hose from the holding tank.

I want to do the install the right way...do I cut a 2" hole in deck then dig out core an additional 1"...then fill with epoxy, let cure and then redrill the 2" hole plus three smaller holes for the fasteners through the deck......or do I drill out a complete 3" hole, totally fill it with epoxy then drill the larger hole and fastener holes in the hardened epoxy?

Should I be adding any strengthening agent to the epoxy?

All ideas appreciated.
Click to expand
A) cut a 2" hole in deck then dig out core an additional 1"...then fill with epoxy, let cure and then redrill the 2" hole plus three smaller holes for the fasteners through the deck.....

This is a lot stronger than doing it the other way, which only leaves the edges of the epoxy plug holding it in place. This has the two skins and the edges holding it in place.

B) First, coat the remaining core with unthickened epoxy. Then you want to fill with thickened epoxy. Thicken it with colloidial/fumed silica or cabosil.

The reason for coating it with unthickened epoxy first is to prevent the core material from trying to leech/wick epoxy from the thickened epoxy. Unthickened epoxy is pretty brittle and chips and cracks a lot more easily.
 
S

stx203

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Oct 15, 2009
58
Oday 25 Tall Rig Fin Keel Chesapeake - Middle River, Md
sailingdog said:
A) cut a 2" hole in deck then dig out core an additional 1"...then fill with epoxy, let cure and then redrill the 2" hole plus three smaller holes for the fasteners through the deck.....

This is a lot stronger than doing it the other way, which only leaves the edges of the epoxy plug holding it in place. This has the two skins and the edges holding it in place.

B) First, coat the remaining core with unthickened epoxy. Then you want to fill with thickened epoxy. Thicken it with colloidial/fumed silica or cabosil.

The reason for coating it with unthickened epoxy first is to prevent the core material from trying to leech/wick epoxy from the thickened epoxy. Unthickened epoxy is pretty brittle and chips and cracks a lot more easily.
Click to expand
If I choose B do I let the unthickened epoxy fully cure before adding the thickened epoxy? How can I get the unthickened epoxy fully into the 1" dugout space and into the core?

Thx for the advice
 
K

Kevin3447

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Oct 26, 2005
116
Oday 28 Detroit/Grosse Pointe Park (O'Day 192, O'Day 28)
stx203 said:
If I choose B do I let the unthickened epoxy fully cure before adding the thickened epoxy? How can I get the unthickened epoxy fully into the 1" dugout space and into the core?

Thx for the advice
Click to expand
When I redid my mast partner area, I used a big syringe, available from where you got your epoxy I bet, to fill up the last part, then taped around the inside of the hole. You could drill the three holes for the fasteners, tape up the inside of the big hole, then shoot epoxy into the three smaller holes to fill it up.

Kevin
 
sailingdog

sailingdog

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Oct 22, 2008
3,502
- Telstar 28 Buzzards Bay
You should do both A & B... and you should just coat the area with unthickened epoxy and then add the thickened epoxy. there is no need to let the epoxy cure. Use a syringe or caulking tube to inject the epoxy into the area.

BTW, I prefer epoxy from Progressive Epoxy Polymers in NH, over West Systems, since it is far less expensive and quite good.
stx203 said:
If I choose B do I let the unthickened epoxy fully cure before adding the thickened epoxy? How can I get the unthickened epoxy fully into the 1" dugout space and into the core?

Thx for the advice
Click to expand
 
jibes138

jibes138

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Jan 27, 2008
3,092
ODay 35 Beaufort, NC
Get your epoxy from Merton's in Springfield, Ma. Joe is an old friend of mine and has been advertising in Soundings for probably 20 years. Best prices around I'll bet.
You could also try a small painters brush to work the epoxy into the hole. A syringe should work fine also. A 2 inch hole is pretty large so you will have plenty of room to work. Be careful not to mix too much epoxy at once in a small container. The reaction is exothermic and it can kick over quite dramatically, hot enough to burn you and instant solidification. Working time is temperature dependent so cooler epoxy will give you more time before it sets up. By cooler I mean like 50 degrees. It alos increases the viscosity. Mix the additive either the colloidal or cabosil to obtain maybe a peanut butter consistency, should be pretty thick. Tape a piece of saran wrap or waxed paper to the bottom of the hole until the epoxy cures to hold it all in position.
 
S

stx203

.
Oct 15, 2009
58
Oday 25 Tall Rig Fin Keel Chesapeake - Middle River, Md
jibes138 said:
Get your epoxy from Merton's in Springfield, Ma. Joe is an old friend of mine and has been advertising in Soundings for probably 20 years. Best prices around I'll bet.
You could also try a small painters brush to work the epoxy into the hole. A syringe should work fine also. A 2 inch hole is pretty large so you will have plenty of room to work. Be careful not to mix too much epoxy at once in a small container. The reaction is exothermic and it can kick over quite dramatically, hot enough to burn you and instant solidification. Working time is temperature dependent so cooler epoxy will give you more time before it sets up. By cooler I mean like 50 degrees. It alos increases the viscosity. Mix the additive either the colloidal or cabosil to obtain maybe a peanut butter consistency, should be pretty thick. Tape a piece of saran wrap or waxed paper to the bottom of the hole until the epoxy cures to hold it all in position.
Click to expand
Thanks for all the advice...one last question...how long do I let it cure before I go back and redrill the holes in the epoxy?
 
sailingdog

sailingdog

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Oct 22, 2008
3,502
- Telstar 28 Buzzards Bay
Depends on the ambient temp and what epoxy you used as well as what type of hardener you used. :D

stx203 said:
Thanks for all the advice...one last question...how long do I let it cure before I go back and redrill the holes in the epoxy?
Click to expand
 
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