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I got the transom all cleaned up and ground down. There was a flap of roven that I had to rebond with thickened epoxy. It was a minor mistake that I make when trying to remove the plywood.
I ground out and reamed out all of the larger holes in the back. I then ground down the edges so that I wouldn't have to do it when the core was in risking digging in to it too much.
Here is a shot of the template and the uncut 1.5" Coosa Board bluewater 20. To make the template I got the general shape from the reassembled pieces of the old core that I had removed. I then adjusted it with lots of measurements. When I traced it on to the coosa I drew a fat line and cut to the outside so that it would be slightly wide.
When I placed it in the boat it was tight in a few spots, but a sureform plane made quick work of adjusting it so that it fit in with 1/8" to 1/4" gap around the edges. I cut the notches in the back sides so that it would slide in from the top.
I left those side pieces and cut the core slightly short in order to accommodate
the transom cap. In theory it will slide on top and I can use those side flaps to help get the camber right.
After it was all vacuumed and wiped down with acetone I laid one sheet of 1.5oz mat up against the inside of the transom. I then
toweled on catalyzed resin thickened with cabosil and mill fibers with a 1/4" notched trowel. I wish that I had put a bit more around the edges of the old notch.
I then slid in the new core and pushed it up against the putty. I then clamped it with the 2x4s and 3/8" bolts and fender washers. I let this set overnight.
