Filling in oversized plate bolt holes – Part II

In the previous segment, I decided to glue some dowels into small bits of plywood to create a mould for filling in the plate holes with epoxy. Next, the moulds got a coating of paste wax so the epoxy wouldn’t stick to them:DSC09337

Now, how to get these things located exactly? The hole in the washers is too small for them to poke through, so I grabbed a cheap washer of the same size and reamed it out with a 7/16” drill:

DSC09334

Now I could line up this reamed out washer with the circle I’d drawn around the real washers, and poke the dowel through it:

DSC09339.JPG

Then, clamp the base in place:

DSC09340.JPG

So before I go mixing up epoxy, I try to get everything ready to go.  As for the choice of filler, a “cold weld” epoxy was a pretty obvious choice (JB Weld is what I had handy).  It’s quite strong, and will look good when painted over with fresh gold leaf.  JB Weld has a pretty long open time, but it’s always better to be prepared.  My main applicator was just a piece of stiff poster board cut to shape and gently folded down the middle.  I also grabbed a small piece of steel (cut from a windshield wiper spring) for “detail” work.

DSC09342.JPG

With the pasteboard I could scoop up a glob of epoxy and let it flow down into the hole.  The small piece of steel was useful for pushing the epoxy down into narrower gaps.  At this point I also gathered up my safety equipment — disposable nitrile gloves, a respirator, and goggles.

I used a kitchen digital scale to measure out equal amounts of the two parts.  Note that when mixing any epoxy it’s important to keep the proportions as exact as you can!  Otherwise you end up with unreacted material and thus a weaker bond.

DSC09345.JPG

To be continued in part III.

2 thoughts on “Filling in oversized plate bolt holes – Part II

Leave a Reply

Fill in your details below or click an icon to log in:

WordPress.com Logo

You are commenting using your WordPress.com account. Log Out / Change )

Twitter picture

You are commenting using your Twitter account. Log Out / Change )

Facebook photo

You are commenting using your Facebook account. Log Out / Change )

Google+ photo

You are commenting using your Google+ account. Log Out / Change )

Connecting to %s