Bronze thru hull replacement

Springbok

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13 Jul 2023
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Decided to replace the they hulls on my boat. Was a pig of a job to get them out as they and the backing nuts were glassed in - probably the original bronze ones from boat manufacturing 40 odd years ago.
They looked tired and the valves were sticking and started look a bit green, was surprised when I cut through them with dremel that they were almost certainly still good for a few years yet and could have just replaced the valves.
After some research online I’ve settled on Groco inline valves and thru hulls (no space to fit the flanged valves unfortunately)
Plan is to build back up the glassed in backing plate with epoxy resin mixed with 404 filler (where I’ve ground away to get to the backing nut)
Probably bond a small round piece of G10 over it
Clean hole up with hole saw
Light coating of epoxy resin to seal it up
Mount new thru hull with either 3m 4200 or 5200 (expect never to remove thru hull again in my lifetime)
Thread sealing not sure on yet but have previously using loctite 542.
Or possibly a bit of loctite and ptfe tape - but really looking for that fit and forget seal.
Any suggestions or better ways to do this?
 
That sounds OTT. As you say completely unnecessary to replace glassed in bronze through hulls, but now you have done it fit either DZR or composite (Tru Design). Expensive bronze Groco have no real advantage from a corrosion point of view, although the valves are probably better designed. Just level up the area around the hole, not really necessary to seal with epoxy although if you are using it for the build up no harm in running a bead around the exposed laminate. However there is no danger of water getting there if you use a good sealant.
 
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