INVESTIGATOR 563

Part 3 - cleaning out the old and in with the new sikaflex, and an unanticipated problem My sikaflex would not come out through the nozzle end and I ended up scooping it from the back end (it was in one of those toothpaste-like dispensers). I rolled it up* and placed it across the top between the backing plate and the boat and then I used the backing plate to push the stuff past the bolts. A bit more added on the bottom saw it done.

* I was thinking how handy it would be to have 'sikaflex' with the consistency of play dough or plasticine.
I needed help to do up the nuts but was able to undo them by myself. As you can see, I have lots of excess sikaflex. I'll let it cure and I may trim it with a razor blade. I am happy to see some around the bolts.

An unanticipated problem
I used a 5inch holesaw, it was the biggest blade in the kit but it is too small for my screw-up inspection port. I did not allow for the size of the frame making up the port only the hatch itself so I have begun sanding the hole bigger but I might need another drill fitting to speed up the work. I will post more pictures and text when I get back to the job.

Thanks for detailed pics Peter . Have you considered using cover plates screwed on to cover the holes . You could make them from , stainless or plastic any size or shape you want. Just a thought to save a lot of work.

That's not a bad idea, Ozzie. I also thought about reusing the nice circular fibreglass panel I had cut out with the hole saw. But I had the inspection ports anyway and thought about the advantages of being able to ventilate the back of the boat easily by simply unscrewing the hatch. See Steve's pictures earlier in the thread.

I have just installed a hinged rectangular access hatch on mine to replace an old wooden hatch the previous owner had intsalled. Will post a picture when I can. It does look great and gives great access.

Part 4 - Fitting the outer ring

The challenge of making the hole a bit bigger required the purchase of a new drill fitting which basically sanded the hole into a larger size. I placed the transparent cover over the hole and used a pencil to mark the size required. The picture shows the job done. I used silastic and then attached the outer ring with 3.5mm screws, washers and nuts. It looks good.

Part 5 - Finishing off

In retrospect I think I placed the hole a little lower than I should. I needed longer screws for the two lower mounts. The fibreglass was thicker here. To finish off I used a little boat grease on the threads of the screw-on transparent cover. It seated firmly.

I am happy to report that after being in the water for nine days straight, the bilge was bone dry. The repair worked.

Goodness, its been a while between drinks.