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(or what I did on my summer vacation)
Not getting any sailing in this summer and not making quick progress on the bailers. There is probably only a couple weekend's work here, but life and rain and work interfere.
After struggling with making pieces of Trex to fill the gap between the inside and outside hulls, I went back to Boston Whaler's original description of the bailer construction (here: http://www.ruach.net/HarpFAQs.html#BailerRep). They just carved the foam out and covered with gelcoat. The problem we have all been having over the years is that the gelcoat cracks, admits water, and then you're on the road to waterlogged.
So I figured, "What the hell?" Instead of re-thinking the entire thing, I decided to refill the entire bailer area with foam, then cut back the foam and put glass mat and epoxy on the facing edges. The mat and epoxy should hold back the tides for the next 20 years or so.
First time using 2-part foam for me. Fun stuff, but you have to be quick! I used the 2lb/cu.ft. foam specified by BW for repairs. Since it expands to over 20 times its liquid volume, I only had to use 3 oz of liquid foam for the void space around the bailers. As you'll see, it is easy enough to take a couple of pieces of scrap, wrap them with saran wrap (foam won't stick to it), attach with a long bolt and wingnut. Drill a hole for the funnel, mix and pour. Then stand back!
The foam expanded and started to ooze around the edges within 2 minutes. Within 5 minutes it was hard. I let it sit for 10 minutes before disassembling the forms and moving on to the other side.
This week if I get time - carve back the foam 1/2 inch and fill with shredded glass mat and epoxy. Then finish with gel coat.
Bob V
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Bailer Repair