I spent two hours last night plugging all these hundreds of holes with very thick epoxy. I've been using a mix of 403 fibers and 406 microspheres -- the logic being the former adds some dimensional strength and the latter more hardness. I pretty much just spoon in the two in roughly equal amounts until I get the consistency I want for minimal runs. Last nights batches were almost peanut butter consistency. So thick in fact that I struggled to get the mixture into the 10ml plastic pipettes I was using. I fitted a 200 ul Eppendorf tip on the end of the pipettes and then used some modest air pressure from my compressor to drive the mix into the holes. It was a lot like piping a cake (never having done any piping....).
One thing I will do differently on the next boat is use stainless steel screws for all these temporary screw clamps. The cheapo Home Depot screws I used often lost their heads when I tried to back them out. The *worst* mistake I made was getting epoxy in the head slots. Those I generally had to drill out, which was both very slow work and often made a mess. I tried getting the problematic screws out from the inside, but there just wasn't enough to grab onto and provide sufficient torque. Longer screws might help in this regards. In any case, my cheap #6, 3/4 inch screws were not up to the task, so I'll try something else next time.
The second layer done. Hurray! Definitely both a small and a big step. I started filling in some gaps between the layers of plywood and the hog with the left overs from the hole-epoxy injection process. It took me a good 2 hours between mixing, plugging and smoothing the excess.
Another view. Time to order the Dynal sheathing and get started smoothing and filleting (spelt right?)
