Use a warmth gun as necessary to assist in eradicating the skin with out damaging it. Long skinny wedges or lengthy skinny metal flat stock floor to a chisel finish might assist in removing also. Cut via the fiberglass with a router, round saw or grinder. Preset the depth of cut carefully in case you are not changing the whole core.
Home made instruments similar to a grub hoe or an adz can be used to take away the stubborn perimeter areas. When you’ve eliminated as much of the wooden as you’ll be able to, sand the surfaces of the exposed fiberglass pores and skin to show recent fiberglass laminate.
Because the opening in the transom is smaller than the plywood core required for the repair, you’ll need to replace the core in pieces involving 3 or 4 layers. Multiple layers are required so the butt joint or joints in any given layer may be staggered and isolated from joints in an adjoining layer. This staggering of the butt joints in the plywood layers helps to keep up core strength as if it was a continuous stable piece of plywood. This technique also requires that the plywood core be laminated in place quite than put in as a full-size piece. This doesn’t current a big drawback because most transom replacements require multiple layers of plywood to attain the required thickness.
Remember to make use of multiple small batches of epoxy quite than large batches. Epoxy in mass generates heat and becomes unusable if not spread out rapidly into thin films. The layers could be glued in place suddenly or one or two layers at a time. Use clamps, screws, wedges or prop sticks to drive the laminates collectively. Bolts with nuts and outsized washers can be utilized in locations where holes will eventually be required. Be sure all elements, tools and clamps are within simple attain.
Be positive you and any parts of the boat you do not need to get epoxy on are protected. A 1½”-thick core can be replaced with three layers of ½” or four layers of 3/8″ plywood. If marine grade plywood is not out there, use multiple layers of AB grade exterior plywood. Exterior grade plywood might have extra voids within the internal layers of veneer than true marine grade. Because of this you will need to use more layers of thin plywood to build up the required thickness. In other words, use 4 layers of three/8″ or 6 layers of ¼” plywood to build up a 1½”-thick transom instead of three layers of ½”. Be certain to fill any voids within the plywood edges with thickened epoxy after the panels are minimize into shape.