Wow! That IS a project boat, isn't it? Well, lemme help where I can.
JonathanW wrote:
1. The outside of the port hull was sliced through by (what I'm guessing was) a saw blade on a weed eater. The slice is about 18 inches long and full thru for most of its length. I figured to dremel-grind it out and fill it with West Systems epoxy & angel hair mix. My question is whether a surface repair is good enough or if I should cut an inspection port on the top or side of the hull to add backing or interior support? Is there enough stress there to warrant it? Hate the idea of putting a port where one's happily not been for over 30 years.
I wouldn't hesitate to put a port there. Then I'd clean the inside of that hole really well and put a layer or two of fiberglass on the inside. Then I think you'd be okay just putty an epoxy / high-density filler mix (flox) in the hole after that, but alone I don't think the flox would be strong enough.
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2. Worse part of the boat is that about 3 feet of the forward port (snip)advice on that? Should any other reinforcement be added?
I think that's all you really can do, is do your best with a few layers of glass in that area. You'll probably have to sand down the existing deck a bit to give the glass a lot of surface area on the deck to grab and then to fair it even.
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4. Second bad hull issue is damage and delamination around the port stern. The corner is ground-down from damage with delam leading inward. Less obvious is a 'mushrooming up' of the hole for the rudder pin. Aside from grind and surface repair, should I try and drill it out and add some sort a bushing to reinforce the hole? Looks like the gungeons are taking the stress...
If the deck is soft from delamination, you'll want to fix that. There are lots of threads and something in the FAQ about soft spots. I don't think the pin is taking much extra stress from the soft deck because the bracket on the stern just below the deck takes most of that load, but Matt Miller will be more helpful there.
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5. The front crossbar has 6 patterned holes on both its port and starboard sides, just foreward of the centerline of the bar. Could anyone tell me what they might have been used for? At some point in its life the boat was retro-fitted with a turbo jib; maybe related?
The only thing I can think of is traveler tracks, but then why would they have been removed?

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6. Sail number does not match the hull number. In its production configuration, would this number have matched? If I buy a new main seems it ought to match, yes?
They don't always necessarily match. Just whatever was lying around at time of shipping is my understanding. I'm lucky enough to have H16 hull#3404, sail #3403 and I, too, have been wondering just what I'm going to do when I get a new sail. Hehehe
Good luck!