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Discussion Starter · #1 ·
Skimming across the surface of the water at nearly 100 mph takes a toll on the bottom of the boats. The last heat of the season, in some rough conditions, I came back to the dock with a hole in the bottom of the sponson. Finally got the chance to get the boat in the garage and fix it for the upcoming season. Here are some pictures of the repair process.

I used 5 mm marine/aircraft quality plywood, West System Epoxy with Micro-bubble filler (when needed), Fiberglass, and some rattle can epoxy paint. Took about two days to complete the bulk of the work, then several days of working for an hour or two then waiting for epoxy to dry.

First race of the year for the boat is June 22nd & 23rd. Racing for the Summer Nationals! Hope it floats again! lol
 

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Discussion Starter · #3 ·
Final repair pictures! I am hoping that we fix an issue we have been experiencing with this sponson. One two prior occasions I came back into the pits with layers of the plywood chipped off in the same spot. We think it is due to the lack of support behind the plywood. I added another frame for support at the leading edge of the patch, and added a second layer of plywood from the tip of the sponson back to the middle of the new patch. Only time will tell if the problem is fixed... If not it will be back to the drawing board!
 

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Maker of sawdust
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pink foam

Support or lack of put some pink or white it's half the weight and just as strong in the sponson without anything behind it the skin is fatiguing. when I worked for a boat builder we used white foam blocks to support Chris Crafts while working on them.

Jerry
 

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Discussion Starter · #5 ·
Support or lack of put some pink or white it's half the weight and just as strong in the sponson without anything behind it the skin is fatiguing. when I worked for a boat builder we used white foam blocks to support Chris Crafts while working on them.

Jerry
Thanks for the reply. In the one picture of the cleaned up hole you can see the baton piece I positioned the small piece between the existing piece and the new patch. I added the second layer of plywood to add some strength. It is going to add some weight, but only 2-3 lbs.

What is the "pink or white" I haven't heard of this stuff but would be interested in learning more.

Thanks again!
Rich
 

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Discussion Starter · #6 ·
Just saw the title of your prior post about the foam and guess that is what you were referring too. I race other boats made out of foam laminated in either fiberglass or carbon-fiber. Since this boat is older and was made of 5mm plywood I just repaired it with that. The foam pieces that I have in my shop are much thicker. I agree it would have been stronger and weighed much less, but I am not sure if I could have gotten foam that thin.

Thanks!
Rich
 
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