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Catalina/Capri 25/250 Sailor's Forums

Catalina 250 Specific Forum

Cutting into fiberglass???

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sailgal
Captain

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USA
400 Posts

Initially Posted - 08/06/2003 : 11:03:40

I want to install a shore power inlet similiar to Als<img src="http://im1.shutterfly.com/procserv/47b3d803b3127cce899b542c5f600000001610" border=0>on the side of my sailboat.
My question is what type of tool to use to cut such a large round hole into the fiberglass. I was told in the past that you can send out cracks from your cutting site. What tips, or concerns can anyone provide me with this type of project. Thanks!

Suzie, Tropical Sleigh
<img src="http://im1.shutterfly.com/procserv/47b3da07b3127cce96a441e875780000001010" border=0>
WB #619 Sarasota FL.

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Bryan Beamer
Master Marine Consultant

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USA
1038 Posts

Response Posted - 08/06/2003 : 11:16:39

I use hole saws that can be purchased at any hardware store i.e. Lowes Home Depot.

I have installed cockpit speakers, a power inlet similar to what you are installing & a phone/cable inlet. They are easy to use and can be powered by a 1/2" chuck cordless drill.

The pilot bit on the hole saw is the most important part. Make sure it is a new heavy duty and sharp bit.

Bryan Beamer
<img src="http://im1.shutterfly.com/procserv/47b3d935b3127cce8ab87c3b48020000000010" border=0>
Daylight Again
C250wk #495
2003 National Champion

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Dave B
Admiral

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Mali
863 Posts

Response Posted - 08/06/2003 : 11:17:28

Use a hole saw in a power drill. Drill a small pilot hole through the place where you want the hole, and use the hole to center the hole saw to cut part way in on both sides. Start VERY gently to spare the gelcoat around the hole. You should end up with a very clean, perfectly circular hole.

Dave Bristle, 1985 C-25 #5032 "Passage" SR/FK/Dinette/Honda in SW CT

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Bill Holcomb
Admiral

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USA
769 Posts

Response Posted - 08/06/2003 : 11:36:23

Hi Suzie,

In addition to what Bryan and Dave have already posted, consider applying adhesive tape to the area you are going to cut the hole in. The tape helps reduce chipping of the gel coat as you start the hole.

Bill Holcomb - C25 Snickerdoodle #4839

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Steve Milby
Past Commodore

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USA
5909 Posts

Response Posted - 08/06/2003 : 13:37:33

You could practice cutting a couple of holes in a piece of masonite or similar material, to give you a little self-confidence before you make the cut in your fiberglass. Also, there are cheap hole saws and good quality hole saws. Get a good one for this job.

Steve Milby "Captiva Wind" C-25 T/FK #2554

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sailgal
Captain

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USA
400 Posts

Response Posted - 08/06/2003 : 15:10:44

Hole saw it is! Hope to get to this project over the weekend. Thanks guys!!

Suzie, Tropical Sleigh
<img src="http://im1.shutterfly.com/procserv/47b3da07b3127cce96a441e875780000001010" border=0>
WB #619 Sarasota FL.

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Sea Trac
Master Marine Consultant

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Vanuatu
1357 Posts

Response Posted - 08/06/2003 : 15:36:03

Suzie,

I'd also recommend that you wear safety goggles, a long sleeve shirt, and maybe even gloves. The fiberglass dust gets everywhere, and is especially painful in the eyes...especially if you where contacts!

J.B. Manley, Antares '85 FK/SR #4849
Grand Lake O' The Cherokees, NE Oklahoma

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mday
Navigator

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197 Posts

Response Posted - 08/08/2003 : 01:30:28

Suzie,

I cut a large hole for my autohelm control unit with a hole saw too. It worked very nicely, but I used a heavy duty 1/2 inch drill. I'd highly recommend the "heavy" equipment. A 3/8 inch drill is a little light-weight for a big hole saw and you'll finding yourself fighting to keep the drill in line.

I didn't have any serious chipping around the front end of the hole and the back end was inside the bulkhead.

Good luck with the shore power install!

Max

Max Day
C250 WB 380
Lake Pleasant, AZ

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Ben - FL
Admiral

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880 Posts

Response Posted - 08/09/2003 : 06:59:55

Anytime I get near fiberglass, I use babypowder on my exposed skin to keep the fiberglass from itching. The powder fills up your skin pours so the glass cannot. It works great every time I have to get in an attic.

Safe voyages,
Ben, FL s/v Chick-a-pea C250wk
<img src="http://www.members.aol.com:/benraye/pictures/fullsail.jpg" border=0>

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Arlyn Stewart
Master Marine Consultant

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USA
2980 Posts

Response Posted - 08/14/2003 : 14:11:14

Bill always provides good advice and I agree fully about using some tape to cover the work area first. It will keep tools from scratching the surface and will retard flaking from the edge of the cut hole.

Steve is also right...there is considerable difference in quality of hole saws. A good arbor and hole saw can cost half a boat unit for a larger size hole. The arbor is a good investment but another idea is to hire a rigger to make your hole. He will have the hole saw and the cost may be the same as the purchase of the good tools.

Arlyn C-250 W/B #224
<img src="http://www.stewartfam.net/arlyn/rr.jpg" border=0>
N/E Texas and Great Lakes

[url="http://www.cox-internet.com/arlynstewart/"]Arlyn's C250 Mods n Cruisin Stories[/url]

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Notice: The advice given on this site is based upon individual or quoted experience, yours may differ.
The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.