Repairing a cowl for a 25hp outboard using fiberglass cloth and epoxy. First mask off the area around the repair. Epoxy is easy to get off when its wet, but you have to sand it off if you let it cure. I dry sanded the area inside the tape with 60 grit sandpaper. I then mixed West Systems 406 filler in to the epoxy untill it was about as thick as wet tooth paste, then spread it out using the mixing stick into the crack making sure to get it inside the crack. Then i took the fiberglass that i cut before mixing the epoxy and layed it down in place and spread it around with the mixing stick, then i took the spreader tool and spread the cloth up and down and left to right then right to left down to up. Then i did the same on the inside cloth. Next i put the last cloth on the outside (1 on the inside 2 on the outside) and pushed the cloth in place while spreading the epoxy. i worked in the shade to keep the epoxy from drying as quick when i was done with the epoxy i set it out facing the sun on asphalt for extra heat... after a few hours in the sun and when it felt dry and strong, i sanded it with 60 grit to fair out the repair. Last i put 2 coats of rustoluem high gloss on both the inside and outside. the repair is now done and no more bugs or water can come in!
sanded
inside
glass
wet out 
all done for lay ups 
inside painted 
outside painted 2 coats 
hard to see! 
