remember the key here: It is full of foam in the hull. It was not cleared away. It inevitably got into the puddle and the welder probably had to go over it a dozen times to get it to burn away enough to close the weld. Hence and ugly weld. Compare to the two that have a nice bead, although cracked.

You are correct however if I read you right, that he should have cleaned it up and left it at least decent looking.

I already informed the owner that I cannot do this repair for the reasons I stated. However I would like to propose a non-welding solution. Do you have one in mind?

Thanks,

Tony

Hi again,

is such patching done from the inside or outside, or both? There is a welders forum that I use to communicate with other welders. One of them mentioned a material called 3M 5200. However after calling 3m and speaking with them, they say a marine epoxy is a better route as their product is not designed for large patches.

Thanks,

Tony

Thanks for the replies. I am going to bow out of this job because I am not setup for maneuvering a boat in the manner you describe. I called the factory and they revealed the reason for the bad weld job. The boat has foam along the bottom. The stuff was melting right into the puddle and it was probably the job from hell.

The boat would have to have the stuff cleaned from around the welding area which involved major surgery removing all the stuff from inside, seats, trim, floor, etc.

This is not un-doable, just that I did not quote based on that amount of work.

Attached are a few more shots.

Thanks again,

Tony