by GreenLake » Tue Mar 27, 2018 3:25 am
Tom, this forum is focused on a particular type of boat, the O'Day DaySailer, and all its models. That said, we don't usually kick out anyone just because they have the "wrong" type of boat - however, as long as it doesn't distract from the focus of the forum.
Your question is fairly generic and the answer applicable to any kind of fiberglass repair.
For sources of information: if you spend some time reading the older posts here on the forum you will find similar projects discussed and might come away with something useful for your project. You can even go back ten years and the advice would not be out of date.
That said, there are (at least) two manufacturers of epoxy (the go-to material for making these repairs) that have published booklets on how to effect a repair. They are West System and System Three. Locating them on the respective websites, downloading them and reading through them should be your first step.
I don't know this type of boat (see opening statement above) but if that crack flexes when you put load on it, you have damage that goes deep and you will have to remove enough of the white gelcoat so you can see where the laminate is milky (broken) or clear/dark (good).
After you've done your assigned reading, you will know how far from the edge of the good part the repair will have to extend.
This will most likely mean removing the fitting - which may be bolted into a backing plate that's drilled and tapped. That would complicate things.
If optics aren't your main concern, it may be easier to apply a patch on the outside and then use longer bolts, if necessary to reach the same backing plate. Be generous in the dimension of the patch, extending it 2-3" down the sides and also fore and left and right of the cracked area. (Remove gelcoat for better bond).
Put a few layers of laminate, each a bit smaller, so you get a "stepped" and not an abrupt transition.
Paint when done for UV protection and replace the fitting. (Waxed bolts left in place during the repair will prevent the holes from filling).
Trying to make an invisible repair might be that much more challenging and unless you are trying to restore an old boat to pristine condition I might question the need.
Good luck.
~ green ~ lake ~ ~