View Full Version : Hack Speaker hole repair

11-17-2010, 02:10 PM
I posted about this problem a long while back on another site.
Two owners back some genius cut into my dash on my boat and installed some 1980's white polyplaner speakers.
, I removed the speakers and mad 5X7 inch pad's to cover the holes.
It looks ok and was a great TEMP fix. after more suggestions I have a long term plan for wrap around dash pad's.
The structural integrity needs to be made closer to 100% again,with the pads Bolted in its about 30%, still not good enough to prevent further stress cracking.
so taking advantage of the sunshine I began.
With the help of some very thick glass mat, Courtesy of 454_Blue_boat..

lets begin, heres the nice hole in the pass side.

1st I cut a template out of 1/2 inch ply, but its to thick to bend to the contour.
so I went with 3/8 inch (i can sand the contour on the front after wards)

then I began layering the heavy glass from behind.Resin, heavy mat, resin, heavy mat, resin liter weight mat, then a thick coat of resin.....

This was taken after 2 layers of glass...

I plan on tomorrow (weather permitting) sanding the front area to get the contour back, then laying 1 layer of lite glass over it.

after that sanding then filling with glass type bondo, and putty....

11-17-2010, 02:36 PM
Nice job Michael!!!!
You're gonna have fun sanding!!! I'll start cussing out them hacks for you now!!!!

11-17-2010, 02:48 PM
I don't know what I'm doing but figure I can make it any worse....
I took advice form several people and just jumped in... since I don't have a shelter for my boat (yet) i did also make a skeleton to go under my heavy tarp....

I don't think the sanding is gonna be to bad as I am only going 1 inch past the repair all around in the front. I already figured I would use a dremel sanding drum to shape the wood into a concave... then just lightly glass it and fill it up flush....... if it comes out cleanly I may try to match the gel coat after the 1st of the year. if not I'm going to go with my original plan of making wrap around pads on both sides...

worst case is it will be stronger. and the holes covered and filled.. that was my original goal...

11-17-2010, 04:56 PM
good work michael, I only have one bit of advice. Skip the thick layer of resin! a thick layer of resin is much weaker then a thin layer. Thick will crack (when not reinforced by glass fiber) thin resin can flex. use a little squeegee or bondo blade, and make sure you sqeeze what excess resin you can out of the layers. this makes the repair stronger, lighter, and last much longer. :)

11-18-2010, 04:24 AM
OK very good advice, the passenger side is the trial and error side.... I have small squeegees from tinting windows, that should work.