Source:

Equipment Required

• West System Epoxy Resin 105
• West System Fast Hardener 205
• West System Colloidal Silica 406
• West System Syringes
• Dremel 400XPR with Flexible Wand
• Dremel Bit #115 5/16" head with 1/8" shank
• Dremel Bit #654 5/16" head with 1/8" shank
• Brad Point Drill Bit
• Duck Tape
• Countersink Bit

Procedure

1. Close the underside of the deck penetration with duck tape.
2. Chamfer the hole in the top skin of fiberglass using the countersink bit in REVERSE.
3. Use the Dremel and #115 bit to remove core material beneath the top skin of fiberglass.
4. Vacuum out the hole.
5. Mask off the top surface of the deck.
6. Mix the epoxy, and inject into the hole using the syringes.
7. Wait 3 to 4 minutes.
8. Suck out the epoxy using the syringes, and squirt the epoxy into the mixing container.
9. Add Colloidal Silica till the mixture runs smoothly off a mixing stick. Does not DRIP.
10. Cut 5mm off the end of a syringe.
11. Inject the slightly thickened epoxy into the hole filling the cavity below the top skin of fiberglass.
12. Remove any overflow from the holes using acetone.
13. Check the hole after a minute or two to see if the epoxy has "settled" due to seepage sideways into voids in the core or between the core and the fiberglass skins. If there is any "settling", top off the hole with epoxy after waiting about 30 minutes, but before the epoxy fully cures. Fully cured epoxy will have an amine blush that must be washed away.
14. Allow the epoxy to fully cure.
15. Redrill the 1/4" hole for the deck fastener.
16. Bed the deck hardware using butyl tape or butyl tape.