Fairing Hull: I decided that before I could sand and fair the chines, I needed to finish restoring the shape of the chine on the front port side.
I'm using bondo, or polyether putty, to finish fairing my port chine. Bondo is great stuff for fairing of just about any surface and the manufacturers have improved on it over the years. In my opinion the best bondo is the new "light" stuff, which is specially formulated to make sanding easier. The main thing to remember when using this material is that it was never intended to fill a void that is over 1/4 inch deep.
I usually mix bondo on a piece of cardboard. I simply glop it out and mix in a enough hardener to make it kick in about 5-10 minutes.
I applied the first coat liberally with a 10" drywall spreader. I was trying to add another 1/16 of an inch to the body to bring it up level with the top part of the chine.
I kept checking the consistency of the bondo until it started to kick or was about the same texture as soap. While it was still soft, I used a bondo shaper blade to smooth the surface. This blade is like a cheese grater and can be bought in any hardware store. I repeated this process multiple times, using the shaper blade and board sander to level the surface. Each application became thinner and thinner and needed less and less shaping and sanding.
I used a small grinder to prep the fillet on the keel before applying the bondo. This tool usually operates at 90 psi, and I had to carefully control my speed as this powerful little tool can make huge gouges in the wood.
I applied the last coat very thinly, in fact at the very edges of the coat the wood grain shows through the bondo.
During my next session I hope to do a final sanding on this area and get on with fairing the chines.