Suggestions For Repairing Damaged Brass Hull Inserts?

[jpswift1]

Hey guys, I need some help and some suggestions if you could help me out. Long story short, at some point in its life, someone used regular screws, not stainless ones in the hood hinge and they were severely corroded and flaking apart, so much so that there waere rust stains on the gelcoat of the hull. I got 2 of the very rusty screws out successfully with an easy out, but 3 of them wouldn't budge and they were so rusted the brass hull inserts spun when I tried using the easy-out on them with the screws still stuck in them.

The 3 holes in a row on the top in the photos are the damaged ones. How would you guys recommend removing the old damaged brass hull inserts and putting new ones in so that it's nice and strong? I figured on cutting out the fiberglass around the hull inserts, getting some new ones, mixing up some Cabosil, chopped strand, and epoxy and then pouring it in around the hull inserts and then putting a couple sheets of 1708 over them, but I wanted to see if you guys had any better ideas before I do that. Thanks in advance.

 

[Myself]

Can you access the backside?

 

[jpswift1]

Can you access the backside?

Unfortunately I can't access the backside.

 

[Pro-pulsion]

You could either scribe lines that you can follow later to pick up the center of the holes again, fill them by getting them brazed and then retap new holes or drill them through completely and put helicoils in

 

[JC-SuperJet]

Can you drill thru and use heavy duty Rivets?

 

[WFO Speedracer]

I would be cutting that thing open and putting in an Aluminum plate , but then me and bodywork are well acquainted .

 

[jpswift1]

Can you drill thru and use heavy duty Rivets?

I can't unfortunately.

 

[jpswift1]

I would be cutting that thing open and putting in an Aluminum plate , but then me and bodywork are well acquainted .

That's what I had in mind initially. I think that's a great idea, but I was trying to avoid all the bodywork. I'm thinking I might just drill the old brass inserts out and fill the holes with cabosil, chopped strand, and epoxy around these brass inserts. They are threaded on the outside so the epoxy and chopped strand have something to bite to.

 

[WFO Speedracer]

That will work but may I make a suggestion, fill the very bottom of the insert with JB Weld and the inside of the threads with wax before you glue them in, epoxy gets in everywhere that you don't want it to.

 

[Mitchyboy561]

Could you drill and tap them one size bigger? Metric or imp

 

[jpswift1]

That will work but may I make a suggestion, fill the very bottom of the insert with JB Weld and the inside of the threads with wax before you glue them in, epoxy gets in everywhere that you don't want it to.

That's a great suggestion. Do you think filling the insert with clay would also be a good idea, or would wax be better?

Could you drill and tap them one size bigger? Metric or imp

That's a great idea, unfortunately the inserts are spinning in place every time I touch them with a drill bit or a tap.

 

[brapperdoodle]

That's what I had in mind initially. I think that's a great idea, but I was trying to avoid all the bodywork. I'm thinking I might just drill the old brass inserts out and fill the holes with cabosil, chopped strand, and epoxy around these brass inserts. They are threaded on the outside so the epoxy and chopped strand have something to bite to.

I've used these as drains for the tray, they are great but very soft. I'd use something like this, the underside is sealed already so you won't need to worry about epoxy running into the threads. They come in different shapes and sizes so you should be able to find one that will fit the way you need it to. female-threaded-collar




If you do have an insert that epoxy will be touching, Install a bolt with greased threads to keep the epoxy from getting inside an insert, its worked for me in the past!

 

[jpswift1]

I've used these as drains for the tray, they are great but very soft. I'd use something like this, the underside is sealed already so you won't need to worry about epoxy running into the threads. They come in different shapes and sizes so you should be able to find one that will fit the way you need it to. female-threaded-collar

View attachment 457478


If you do have an insert that epoxy will be touching, Install a bolt with greased threads to keep the epoxy from getting inside an insert, its worked for me in the past!

Thanks, Seth. And those will never spin when you're tightening or loosening the bolts that go into them because the epoxy will have a very strong hold on the base of these it looks like.

 

[WFO Speedracer]

They are called adhesive mount nuts , available here :

https://www.mcmaster.com/products/weld-nuts/stainless-steel-adhesive-ready-nuts/

 

[brapperdoodle]

They are called adhesive mount nuts , available here :

https://www.mcmaster.com/products/weld-nuts/stainless-steel-adhesive-ready-nuts/

You can also call Rotaloc directly and order specific inserts if McMaster does not have what you’re looking for

 

[Storbeck]

That's a great suggestion. Do you think filling the insert with clay would also be a good idea, or would wax be better?


That's a great idea, unfortunately the inserts are spinning in place every time I touch them with a drill bit or a tap.

You may be able to drill a couple of small holes around the perimeter of the insert, use a syringe to inject jbweld or maybe thickened epoxy into the small space around the spinning insert to keep it held in place, then drill. Carefully.

 

[WFO Speedracer]

Some small holes and inject some red loctite ?