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Outboard well issue

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A264 Clytie says:

My well plug won't fit smoothly into the well, it stands about 3-4 inches proud and fear if I force it I'll never get it out again. I sense the well sides (as opposed to the plug) have expanded outwards. Has anyone else had this problem?

I've sanded both the plug and the well without success.
11:59PM, 13 February 2014 PST (permalink)

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Peter (boat name prowler) says:

I discovered my well had a lifetimes of antifoul build up while stripping it back to grp.

I had slight weeping from the well this autumn from a small wear patch where the front of the outboard vibrates / pushes against the grp while motoring forward, fortunately just above the waterline so only noticed when the boat was moving. So after spooning on a load of fiberglass filler, i was contemplating how to stop it happening again and thought a nice hardwood plate there would do the job, fortunately as i was looking at various thicknesses of wood in the scrap pile the error of my ways dawned that any wood would be to thick. I sanded the filler back well, but still haven't checked if the plug fits....
58 months ago (permalink)

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SHAMAL411 says:

We had this problem but eventually got the plug to come in and out smoothly by removing a lot of material from the plug with an angle grinder. I wouldn't touch the well sides. It helped to give the plug a light coat of thinned paint , where it rubbed off revealed the sticking areas . Add a handle on top (rope) for pulling out. I had to go deep into the resin but it was thick enough , then resurfaced with a gelcoat.
Originally posted 58 months ago. (permalink)
SHAMAL411 edited this topic 58 months ago.

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A264 Clytie says:

Thanks the advice, good idea about the paint test will try tomorrow and focus on the plug.
58 months ago (permalink)

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NormanKlipspringer is a group administrator NormanKlipspringer says:

I believe that many owners have had problems with the plug filling with water which would add to the problems of removal. Many owners have gone for a two part plug - a lower portion which makes the hull outside profile held in place with a variety of fixings, and an inner part which creates the floor of the cockpit. I have a halfway house which is a lower plug which is held in place by the normal engine support plug with a suitable spacer. This of course means that the well is open to the cockpit but the system does work. There are many pictures on this site of different plugs. Either use the Flick index on the main site www.achillesyachts.co.uk or use Flickr's own search facility. Good luck.
Norman
58 months ago (permalink)

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Mike A1 says:

My plug was full of foam which didn't feel damp but did seem to have swelled up. I cut a 4" hole in the top, took out the foam and fitted an access cover to the hole. The plug is now much less rigid and easier to get in and out.
58 months ago (permalink)

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A264 Clytie says:

Attacked the 2 main sides with an angle grinder this afternoon and shaved off a lot of material. The inner well is antifouled so marks the plug where the excessive contact/squeeze is occurring. The grinder plate broke before I could finish however I have reduced the problem by about 70%. Shamsal, I'm into what appears to be pretty thick resin, how did you refinish it as I'm pretty non-techy - I guess I'd have to over grind it to create sufficient space for the new gelcoat? Resin is pretty porous into it?

Norman, I'm very happy with the original plug design and would prefer to maintain that system.

By the way, my plug seems heavier than I remember I wonder if the filling is wet? Anyone know what a plug should weigh?
58 months ago (permalink)

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AchillesHeeled says:

It's probably worth removing the anti foul from the well, that will make quite a difference
58 months ago (permalink)

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SHAMAL411 says:

I finished the bare resin by painting with polyester Flowcoat . Make sure the plug is dry (heat gun) and clean (acetone) before painting. Yes exposed glass fibres can wick in moisture. Flowcoat is quite thick so you will have to make room for it .
Get the plug bottoming freely in the well as even slight sticking will jam it .
Originally posted 58 months ago. (permalink)
SHAMAL411 edited this topic 58 months ago.

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