Category Archives: Boat Repair

Rough Rider

Smiles All Around

By Mike Barnard

For some sailors, there is a common maintenance ritual that occurs every spring—repairing cracks where the leading edge of the ballast keel meets the hull. This annually reoccurring crack is sometimes referred to as a “Catalina Smile” because it often occurs on Catalina sailboats.

The crack can form due to a number of causes but probably the most common reason is the hull isn’t as stiff as when it was new.  Continue reading

The 37th Annual Wooden Boat Festival in Port Townsend, Washington

By Bruce Niederer

Epoxyworks 38

Cover Photo: A good overview of Port Townsend’s busy harbor on a gorgeous September day.

If you are interested in US Maritime history and heritage, you owe it to yourself to visit Port Townsend, Washington. Port Townsend is located 56 miles NNW from Seattle and sits on the waterfront of Port Townsend Bay in Puget Sound. This unique village is known for its sense of community and a lifestyle of “salt water hippies” focused on boats and the sea. Port Townsend is also the home of the oldest and largest Wooden Boat Festival in the Pacific Northwest, perhaps in the US. Truly an international event, Continue reading

Bottom Fairing Adagio

By Greg Bull

Most seasoned sailors would agree that a clean bottom leads to faster sailing. Sometimes it may be necessary to do more than scrub away the algae and zebra mussels, though. In the case of Adagio, 44 years of sailing was starting to ripple the bottom of the boat. Simply put, it was time to fair the bottom. While fairing the bottom of your boat may seem beyond your reach, it is a project that novices and experienced boaters alike can accomplish with a few simple tools and a love of a little manual labor. The first step that I took to fair the bottom of Adagio was to get the main hull tipped up on an angle to make working on it easier. On most Continue reading

The Norway Boat

By Gene Steely

This is the story of a 20′ sailboat manufactured in Norway in 1956 by the Ejvinds Company. This boat sailed from Iceland to the east coast of Canada, then down to Miami. From Miami it sailed south to St. Croix and the Virgin Islands. After a few years in St. Croix it was brought to the Florida Keys 1967 and had two or three different owners. I purchased it in the Florida Keys in 2003 and brought it to my home in Murray, Kentucky for restoration. Continue reading

Common Errors in Fiberglass Repair

By Jeff Wright

While most of our customers are successful when using WEST SYSTEM Epoxy to repair damaged fiberglass, we have become familiar with some common mistakes that are easily preventable. These mistakes are made by both professionals and amateurs. The information discussed in this article is available in our Fiberglass Boat Repair Manual and WEST SYSTEM User Manual, and on the WEST SYSTEM website.


Typical Repair

fiberglass repair

A typical fiberglass repair in cross section.

This diagram illustrates how we recommend laminating a repair after the damaged Continue reading

G/Flex Keel Repair

By Don Gutzmer

Early in March of 2012, a local boat owner called our technical line and asked about repairing his cast iron wing keel with WEST SYSTEM® Epoxy. He asked if a technical advisor would be willing to take a look at the cracks on his keel and recommend the best way to repair it. After looking at the boat I gave the customer a call back and recommended using G/flex® Epoxy. The advantage of G/flex is that it is a toughened system that has a tensile elongation of more than 30 percent, which would prevent cracks from reappearing in the fairing compound. The boat owner then asked if I Continue reading

Chamfer digs the new cabin sole on FUNKTIONAL

Replacing a Small Boat Cabin Sole

By Jeff Wright

The amount of wood used in a production fiberglass boat is significant; it is used for many things such as stringers, bulkheads, floors and backers. Higher quality production boats often use marine grade plywood for these applications but it can still be damaged by long term exposure to water. Continue reading

Small Projects and Repairs

By Jeff Wright

Many of our EPOXYWORKS articles feature projects that our customers have spent years building and represent major personal accomplishments. I also believe we have many customers who, like me, use WEST SYSTEM Epoxy simply to keep an older boat in good repair.

The following are examples of repairs and small projects that I have completed on my personal boat over the last ten years. These would apply to many production fiberglass boats. Since WEST SYSTEM Epoxy has a shelf life measured in years, it is easy to keep it on your shelf and tackle these tasks when it’s convenient. Continue reading

Larson Thunderhawk

By Mick Ignatiuk

Built in 1957, my 15′ Larson Thunderhawk Jr. is a fiberglass runabout reborn. I launched her into the waters of Grass Lake, in Fox Lake, Illinois in late August, 2010. But before this happened, the boat underwent a major restoration. I purchased this boat in August of 2009, after it sat idle for several years, collecting dirt, rainwater, leaves and snow. All that remained was its shell, motor and a rusted trailer. I found a group of Larsen enthusiasts who helped me locate my boat’s original specs, drawings Continue reading

Repairing JESTER. Who’s Laughing Now?

By Greg Horvath as told to Bruce Niederer

The following photos detail some recent repairs made by the owner and crew of Jester, a 2005 C&C 99. Jester is well equipped and has been meticulously maintained by her skipper and only owner, Greg Horvath. Jesterhas only sailed in fresh water and is stored indoors during the winter. She is also the boat I’ve raced aboard here in Saginaw Bay as well as around the Great Lakes including the Port Huron to Mackinaw Race and the Ugotta Regatta in Harbor Springs. Continue reading