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I want this gone! Looking for advise on a fiberglass project.

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I want this gone! Looking for advise on a fiberglass project.

Old 12-28-2014, 06:06 PM
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Default I want this gone! Looking for advise on a fiberglass project.

The livewell on my Robalo 235 is more of a deathwell. It's too small and a poor design for offshore use in SoCal. We typically use 5"-7" Sardines and this thing kills half of them before we reach the fishing grounds most of the time. It's time for it to go and be replaced with a 50gal. Pacific Edge Custom mounted farther forward in the center of the cockpit. I know how to make it go away and have a solid plan to rebuild the inner part of the transom.

I will need to add a section of sole where the bench / livewell was. The existing sole is foam cored glass about 13/16's thick. The new section of sole will be supported by the two existing stringers. Can I use 3/4 marine plywood and build it up with resin / mat? Should I use all epoxy resin or is polyester ok? Do I glass the back or bottom before I adhere it to the stingers? What is the best way to blend it or transition it with the existing sole at the seams? What is the best way to fasten it to the stringers? I was thinking thickened epoxy or Methacrylate. The section will be about 54" X 18".

Looking for some advise from the experts.
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Old 12-28-2014, 06:22 PM
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It's going to be replaced with this, mounted in the center of the cockpit:
Old 12-28-2014, 09:36 PM
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Hmm that looks to be the old Robalo prior to them being sold to Chaparral. Go to the Robalo forum, Mr. Robalo, one of the originators of the company is on there and can help you with the structural aspect if nobody here knows for sure.


http://robaloboatowners.net/forums/index.php?act=idx
Old 12-28-2014, 09:51 PM
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Originally Posted by Notatthe209 View Post
It's going to be replaced with this, mounted in the center of the cockpit:
I put that tank on my Bertram 28 that I had in Peters Landing / Huntington Beach. GREAT tank. Pacific Edge is a great shop, great bait tank builder and the owner is about as helpful as anyone I have ever done business with. Hell, he even gave me GPS coordinates of the best lobster holes in Long Beach harbor. How cool is that!

I cant guess on the structural mods you will need to do. I can tell you that you picked the right tank and builder.
Old 12-28-2014, 10:38 PM
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I don't really need anything Robalo specific. There was another thread about a guy replacing a sole. I just need some general layup or "schedule" advise on replacing a section of sole. I'm sure there are general do's and don'ts and some materials that are better than others. I have done plenty of small repairs using polyester resin and spray on gelcoat so I know how to get the finish. I'll post a build thread when I get started. I would rather get some advise now before I tear into it. I've been stalking all the build threads on here for years, but haven't seen one where just a section of sole is replaced / fabricated.
Old 12-29-2014, 07:21 AM
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Have a professional do the work ...
Old 02-19-2015, 11:57 PM
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Finally got around to working on this project. Started the demo today
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Old 02-19-2015, 11:59 PM
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First cut
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Old 02-20-2015, 12:02 AM
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Dremel tool and an air chisel made short work of the cheapo plastic old tank and foam
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Old 02-20-2015, 12:04 AM
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Going to fix the spaghetti wiring and move a few batteries before moving on with the fiberglass
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Old 02-20-2015, 12:05 AM
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panel
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Old 02-20-2015, 03:59 AM
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Sub
Old 02-20-2015, 04:41 AM
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Can you take a cross section pic of the deck?
Old 02-20-2015, 10:18 AM
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I have this, going to do some plumbing and electrical today. New 1" pickup and seacock to replace the stock 3/4" and a 1200 GPH pump to replace the 200 GPH washdown pump Robalo used to supply the old livewell.
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Old 02-20-2015, 10:36 AM
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I am no expert but have done a few projects using coosa board and laying up with 1708 matt and polyester resin. Coosa is real easy to work with ( just like wood) but lighter and stronger. Looks like you need to glass in a support to forward side of cut and then use stringers and back wall to support. I would just expoxy or glass to stringers. Looks like a fun project, good luck.
Old 02-20-2015, 12:50 PM
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3/4" ply will be fine. I would use epoxy and coat the entire piece well, top, bottom and edges before I attached it to the stringers. If you dont want to ever remove it, go ahead and mix up some thickened resin and cabosil or chopped fiberglas and stick it on the stringers. you should support the edges also and then either fair it in with a layer of glass, or leave a groove and caulk it with 3M 4200. I would have a layer of glass on top for abrasion resistance. that area probably gets a lot of traffic.
Old 02-20-2015, 01:33 PM
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I actually cut and saved the front of the bench to use as the new inner transom so all I really need to fabricate is the floor. 3/4" ply and 1708 is the plan. I will need to glass in some support. The radius of the old/bench livewell was stress cracked all the way around. In some places it's only about 3/8" thick with no core or support underneath it. I will be fixing that issue before patching the sole.
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Old 02-20-2015, 06:45 PM
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Marine ply with glass on top and underside should do it. I would want a lip for the edge to rest on all the way around the new piece of floor as well as a little more support under the deck. It looks like there is raw wood or ply under the old live well, I think I would go ahead and cover it with fiberglass too.
Are you going to try to make it a seamless joint were the new and old floor come together or make it a butt joint (most likely filled with 4200 or 5200)? If you make it a butt joint rap the glass over the edge so you don't have a wood edge. At a minimum cover it with resin.
What are your plans for the bulkhead left after removing the live well? I know it serves a purpose for the engine well but now its just kind of out of place. What would it look like if you cut it all the way out? Possibly build a bench seat/ storage back in place of the old well?
Old 02-20-2015, 08:07 PM
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Agree on the lip but it's going to be tricky. The glass thickness of the existing sole varies quite a bit and it's not sitting level on the stringers. In some places it's one thin layer and in others it's cored with a bottom layer. The new sole section will be glasses in flush with no seams. I'm glassing in the front of the old bench to the exposed side of the splashwell. Another reason I removed the bench is there there was way too much weight back there. 4 batteries, a 30 gal livewell and a bench with two adults sitting on it left the boat stern heavy. I'm moving the two GC2 batteries to the middle closer to the inverter they power and no bench in back means 400 less pounds. I'm hoping that getting 760 pounts off the stern will help with the hole shot and make for a better ride.

Spent all day working on plumbing and electrical. I figure now is the time to do all of this, while I have better access.
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Old 02-20-2015, 08:08 PM
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Old 3/4" sea cock and pick up, new 1".
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