This is awkward.
There is definately going to be a noticable difference between the existing luran and the new fiberglass.
The 1700 stitch matt is pretty heavy and in my hands its feels much thicker than the cloth sold in hardware stores. I cut off a couple squares and built up a 3 layer sample and a 4 layer sample. The goal was about a tenth of an inch since that is about the thickness of the luran cut off. Almost wondering if i should have just bought fiberglass panels from lowes instead and glued that down. The 4 layers version averages out to .023 inches per layer, while west marine says it should be .035.
As far as composites go three layers of 1700 is more than enough for covering foam, but its looking like id have to put down 8 layers to be level (3/16 inch) with the luran. Thats bs. Maybe i squooshed the fibers out while saturating the cloth with the roller and didnt use enough resin, but it got fully saturated.
The panel that got removed weighed 75 ounces, the three layers of 1700 ive cut weigh 40oz and requires at least 80 oz of resin, already going to be heavier when a composite really only needs the one layer. In addition, ive got two coats of neat epoxy over those, but the 2:1 ratio of expoxy to cloth is supposed to include that.
Ill probably know by the second layer how this build up is going to go.
At the very least, the first step will be adding a high density low angle camber fillet between the luran and the foam. That will help transition the glass up and over the lip without a bubble under the glass. It will mostly likely be dremeled out afterwards to add the MMA.
I dont mind if there is a recessed area of repair, but it would probably hold water when left outside.
Additional notes: The total volume of the cut out luran is 180 cube inches, or 0.8 gallons. If i need 0.6 gallons of resin, then that means the remaining 1700 glass needs to be 0.20 gallons or 50 cube inches, thats a cube of solid glass 3.6 inches on a side. My pile of glass when tightly rolled up is about 86 cube inches. I know it wets out so maybe im close?