JDW: WEST System Fiberglass Repair Part I
Here a review of the Video on Part One of 
Fiberglass Repair.
1) Thoroughly inspect the hole and the immediate area to determine the extent of the damage.
2) Remove any loose material.
3) Outline the damaged area.
4) Cut out the area with a Sabre Saw.
5) Bevel the edge of the hole.
6) Measure the laminate to determine the bevel diamter.
7) If possible, a 12:1 bevel is ideal.
8) Grind out the bevelwith a 50 Grit Sanding Disc.
9) Hand sand the inside of the hole.
10) Create a temporary backing for the hole. You will need plywood, soft foam and plastic sheeting.
All should be slightly larger than the repair area. They should be placed down in this order: plastic, foam, then plywood. Prop the backup material into position.
11) Cut a piece of plastic, tape over hole and outline the outside and the inside edge of the bevel.
12) Use the plastic to cut out pieces of Biaxial Fiberglass Cloth.
13) Next, cut out plastic and Peel Ply larger than the biaxial cloth.
14) Mix a batch of West System 105 Epoxy Resin with West System 205 Fast Hardener or West System 206 Slow Hardener.
15) Wet out the entire boding area with the mixture.
16) Beginning with the smallest piece,wet out all the fiberglass cloth.
17) Place one on top of the other on the piece of plastic.
18) Use a Spreader to remove excess epoxy.
19) Flip the patch with the smallest piece down, on a piece of peel ply and plastic.
20) Place the largest piece toward the substrate first.
21) Add 406 Colloidal Silica to the remaining resin-hardener mixture. Mix it to a mayonnaise consistency.
22) Add the mixture to the beveled edge of the repair surface.
23) Place the plastic, peel ply and patch over the hole.
24) Work air bubbles and excess epoxy out of the patch.
25) Remove the plastic, leaving the peel ply in place.
26) Use a spreader to remove any air bubbles.
27) Remove excess resin with a spreader and a solvent-dampened paper towel.
Everything seen here is available at 