This old, neglected canoe was in need of some serious attention. In addition to needing significant body work, a portion of the fiberglass deck had broken off.
We contemplated getting a small sheet of thermoplastic, creating a wooden form, and then using a heat gun to shape the plastic onto the wooden form.
But we already had some fiberglass and the other end cap of the canoe was still intact, so we decided to use the good end cap as our form to rebuild the broken deck cap.
We used some cardboard to build a support edge on the good end cap that we were using as the form, so that the edge lined up with the bottom of the broken end cap.
We taped some clear cling wrap over the good end cap to protect it from the fiberglass.
We test fitted a section of fiberglass fabric so that there was at least a 2 inch overlap underneath the broken cap.
We applied a heavy coat of resin to the underside of the broken cap and set it onto the form. Then continued to build up layers of fiberglass and resin.
It took about 3 or 4 layers of fiberglass to build it up as close to (but not level with) the broken cap’s height.
The plan for the final layer of the end cap is to use Bondo. It’s easier to control while it’s being applied and a lot easier to sand than fiberglass.
Once completely sanded, it will get two coats of white epoxy appliance spray paint.