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I have a 1995 Hobie Cat 16 with badly worn pylons and elongated holes. I would like to stiffen the boat. After reading different fixes including the beer can or cutting board shims or epoxing the boat together. I am looking for some comment on this idea. I have the boat apart now and think I could build up the pylons to their original size with Marine Tex or Bondo. Since some of the fixes include using epoxy to hold the boat together I thought the Marine Tex might hold. There is quite a bit of wear , I measure a difference of 1/8 inch between the top and bottom of the pylon.. I was also thinking of making shims out of aluminum, but they would have to taper from 1/8 inch to 0. That’s why I thought I could build up the pylon with marine tex but I don’t know how long it would hold up. As for the elongated holes, I would drill out the ½ inch holes to ¾ inch. It would take ¾ inch to cover the enlongated holes in the pylon. The only other solution I can think of is the get the hole welded up and just redrill with ½ inch hole. Of course there is obvious heat problems with welding near the fiberglass.
Can anyone help?
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Brig Bill
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