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4.4 Repairing laminates with vacuum bagging In many cases, the same procedures that are used to manufacture new panels can be used to repair damaged fiberglass hull or deck laminate. For most fiberglass boat repairs, vacuum bagging is not necessary to make a repair that equals or surpasses the strength of existing laminate. For highly stressed, lightly built composites, using vacuum bagging techniques to laminate new fabric into an excavated damaged area is an effective way to get a high fiber- to-resin ratio repair that should be as strong as the existing panel. The following procedure describes the use of the vacuum bag laminating process for fiberglass laminate repairs (Fig- ure 4-8). 1. Prepare the damaged area. Using a buffer/polisher with an 8" foam pad and 40-grit paper, grind out all of the damaged area. Remove any delaminated laminate, exposing solid un- damaged laminate. Grind the repair area to a circular or oval shape. Bevel the edges of the cavity to a 12 to 1 angle (up to 50 to 1 for heavily stressed areas or thin skinned laminates). 2. Sealthebackoftheopeningtoprovideanairtightenvelope.Ifitisnecessarytogrindcom- pletely through the laminate to remove all damage, bond a piece of plastic laminate over the back of the opening to back up the lay-up. If a temporary backer is desired, such as in an ex- posed interior area, 833 Vacuum Bag Sealant may be used to hold the plastic backer in posi- tion and seal the opening. Wax the portion of the plastic backer that covers the opening so that it can be easily removed after the lay-up has cured. If the laminate is cored, it may be necessary to seal the core with epoxy. A scored or porous core may make it difficult to draw a good vacuum and should be coated with epoxy to make the surface airtight. 3. Cutanappropriatenumberofpiecesoffabricthesameshapeastheexcavatedrepairarea. The first piece should be slightly smaller than the outside of the beveled edge. Each of the remaining pieces should be cut slightly smaller than the preceding piece with the last piece Rebuild a damaged laminate to its original thickness using multiple layers of fiberglass cloth bonded with epoxy. Back up the opening with an airtight panel that conforms to the shape of the damaged laminate. Vacuum Bagging Applications 28 Fabric layers Mastic or adhesive Plastic laminate Grind a bevel around damaged area Vacuum bag film Mastic sealant Breather fabric Perforated film Release fabric Vacuum gauge Vacuum port Figure 4-8 4PDF Image | Vacuum Bagging Techniques 002150
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