Ryan:

Very good questions. It's simple to drill the holes - just drill through the first layer then it will cut through the foam then hit the bottom layer. STOP at this point and don't drill through the bottom layer or you will have epoxy dripping into your hull when you inject. It's fiberglass, foam, fiberglass. The fiberglass is kind of tough and you have to purposely drill through it.

For your second question, I plan to slightly re-drill each hole with a larger bit for kind of a countersink look so I can dab a bit of gel coat on top. The epoxy resin can't stand the sun for long so you have to cover it up with something. I'll post photos. Paint would also work. I put that truck bed liner stuff over the first hull holes but this time I think I'll just dab some gel-coat on the holes.

I have an idea to mix some powder coat powder with polyester resin to make my own gel coat mix and use that. I have some white and blue powder coat powder I can mix to get close to the blue color. I understand the polyester resin is more resistant to UV so I think I'll try it.

One more thing on the holes - the center hole is bigger to accept a tight fit from the syringe. I got some horse-injection syringes from Tractor Supply locally and I did a test drill with a small bit on a piece of wood. The outlying holes are smaller (1/8"). Just inject until you see the epoxy coming up then put tape over the outlying holes.

Here is something else I may not have mentioned - when mixing the epoxy, I did four pumps of resin, four pumps of hardner and one heaping tablespoon of adhesive powder (the white powder) and mixed it all up. Then I sucked it up into the horse syringe and injected it into the center hole.

I hope this was helpful,

Scott Laughlin
Omaha, Nebraska
www.cooknwithgas.com