An angle grinder with a 40 grit flap disc, works great to make the necessary bevel but makes a lot of dust. Another tool that fits in tight spaces is a 1/2" wide belt sander from Harbor Freight. (The toerail will restrict how far out you can bevel, so I would epoxy a piece of 3/8" G10 to the underside of the deck to spread the load. I'd also consider adding 1/4" blocks under each pulpit base)
https://www.harborfreight.com/53-amp-12-in-x-18-in-bandfile-belt-sander-58155.html You'll need to paint the repair on deck to protect epoxy from UVs. Otherwise it will yellow in a few weeks. Chuck > On 06/05/2026 11:55 PM EDT Randy Stafford via CnC-List > <[email protected]> wrote: > > > A quick question on this Dennis: what tool do you use to create the 5:1 > chamfer? > > Thanks, > Randy > > > On Jun 4, 2026, at 10:57 PM, Randy Stafford via CnC-List > > <[email protected]> wrote: > > > > Thank you Dennis, I understand your instructions. I’m getting that feeling > > I’m about to learn and do something new :) > > > > Cheers, > > Randy > > > >> On Jun 4, 2026, at 1:56 PM, Dennis C. via CnC-List <[email protected]> > >> wrote: > >> > >> First, I think the deck is cored but it does not extend completely to the > >> toe rail stopping a few inches short. > >> > >> Second, what Dave said. First, clean up the two holes a bit. Bevel the > >> edges to at least 5:1. > >> > >> Then lay up some glass on waxed paper with epoxy or vinylester resin about > >> 3/16-1/4 inch thick, cut it to fit from underneath with at least an inch > >> or so outside the hole where you can. Epoxy them in place using thickened > >> epoxy. Maybe apply with a notched trowel to get ridges. > >> > >> Then fill and smooth the deck from above. Cut pieces of glass, lay them > >> in the hole dry, then apply epoxy or resin to the edges of the bevel but > >> not beyond. Let cure then trim any glass threads around the edges by > >> carefully sanding. > >> > >> Smooth with putty and two part glazing putty. > >> > >> -- > >> Dennis C. > >> Touche' 35-1 #83 > >> Mandeville, LA > >> Please help cover the costs of maintaining this list by making a small > >> contribution using PayPal at: https://www.paypal.com/paypalme/stumurray > >> All contributions are greatly appreciated. > > Please help cover the costs of maintaining this list by making a small > > contribution using PayPal at: https://www.paypal.com/paypalme/stumurray > > All contributions are greatly appreciated. > Please help cover the costs of maintaining this list by making a small > contribution using PayPal at: https://www.paypal.com/paypalme/stumurray All > contributions are greatly appreciated. Please help cover the costs of maintaining this list by making a small contribution using PayPal at: https://www.paypal.com/paypalme/stumurray All contributions are greatly appreciated.
