Had a chunk out of my lower unit since I purchased it. Decided to do a fix on it and will share my technique here in case anyone else has a problem similar.

This is what I started with



I took my trusty Dremel and ground the surrounding area so that my "patch" would fit flush and have something to bite into



For my "patch" I used a piece of expanded metal lath that I hammered as flat as I could get it, then cut to shape.



I put some tape on the inside to make a "release" for the epoxy, then a piece of semi-rigid plastic sheet behind that to hold the curve.



Partly fill the area with JB Weld, set the patch in and add more epoxy




I then covered that with more tape and added heat from a lamp to slow down the epoxy from setting to quick in the cold shop.




Let set a few days, then remove tape, sand and fill in any low spots with body filler and you end up with this.



Its a strong fix and cost me a few bucks for epoxy.

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Great job!!! Are you planning on painting it?? Thats a great repair you did...and with the expanded metal should be stronger than before. Just like putting rebar in concrete.

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Doc Holiday; "I'm your Huckleberry" "You ain't no Daisy"

nice job ,good ideal

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The fishing was good,it was the catching that was bad

That looks great and a great idea. Like to see it when a man uses his head for something other than a hat rack. Good job. Billy

Nice job!

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Fair Winds and Following Seas

Bill H. PTC USN Ret
Chesapeake, Va

man thats nice, wish i would have seem this a few months ago. same thing happened to me and i finaaly found a foot and just replaced the whole thing. your one smart cookie! GREAT JOB!!!!