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After I ground all the gel coat off the outside of the transom I found 43 holes in it. This included the engine bolt holes from previous engine's and whatever else they mounted on it. I built up the glass where the cutout was and covered the whole outside with 2 layers of 1808DB.
This is a mold I built for the top cap of the transom. The
material is 3/4in Kledgecell. Only the bottom side is vacuum bagged on the mold.
This was done so I wouldn't have to lay glass upside down. It was then trimmed a
little and bonded to the top of the transom core and around the sides with
epoxy/cabosil/microballons mix.
You can see a piece of 1/2in Kledgecell that is vertical.
It is sticking up about 1/2in above the top panel, so that it
will conform with the original inside toerail.
After the fillets were done, I laid 1 layer of 1808 roven and 2 layers of 1808 DB on the inside. I let it come up around the fillets in the top cap and extend forward on the sides and bottom too. This was hand laid as it would be a real pain to get the bag sealed around the stringers.
This is the transom almost finished. The core is 2in high density Kledgecell. The top cap is 3/4in Kledgecell. I matched the coming from the sides across the top cap. You can see the camber in the cap. The stringers in this boat have no wood. They are foam filled. The new rigging tubes have been installed, one is 3in and the other is 4in. It will make for easy rigging.
