- Removed the head dorade box from the boat on the way home from Highland Park NJ. Eight screws hold the box to the deck. Three long screws hold the metal vent to the deck (why?).
- Removed the remains of the plastic ring that held the metal vent to the dorade box.
- Decided to glass the opening closed, then use a hole saw to create an appropriately sized opening for the metal vent. Will secure the metal vent to the dorade box using flat head machine screws and nuts.
- Washed the dorade box, inside and out.
- Sanded the inside of the dorade box with 60 grit paper, and acetone washed the same.
- Covered the hole in the dorade box for the plastic ring with HomeDepot packing tape. Epoxy does not stick to the non-adhesive side of the packing tape, rather epoxy flows well over the surface resuling in a smooth, highly reflective surface.
- Cut three round sections of 1708
to fill the hole in the top of the dorade box resulting in a thickness of about 3.5mm or just over 1/8".
- Cut three rectangular sections of 1708
to support the glass filling the hole. These sections overlapped the inside surface of the top of the dorade box and part of the starboard and port sides.
- Used WestSystem 105 epoxy resin
and 206 slow hardener
to saturate the rounds, one at a time and place them to fill the hole.
- Continued with each of the three rectangular sections covering the inside surface of the top and a portion of the sides resulting in a thickness of about 3.5mm or just over 1/8".
