Please understand that this is a new technique that is not endorsed by anyone else who has a lot more experience than me with these issues, and I have yet to sail the boat!!! How is that for a disclaimer!!!
So I don't know how it will hold up under fire. Also because I had to cut the port holes to gain access inside the hulls, now there are some 5" potential weak spots in front of and behind the pylons. I did use Hobie designated ports, so I am assuming that cutting the holes, is OK!
I was checking the boat out today, and all seems well. I did not need to do any soft spots on the hull, just on the decks, which are very firm now, with no soft spots remaining!
Using the normal injection of epoxy, one repair job reported that the first time someone stepped on the hull, the hull was soft again, and they resorted to filling the whole hull with foam. This seemed extreme to me, and a potential hazard since the solid foam could become waterlogged, and not provide the necessary floatation, and no good way to dry it out leading to further delamination, or access for further repair.
Using my technique, you can easily regain access to the hull and apply more glue whenever and where ever necessary. This could easily even be done at the sail spot overnight if a weak spot developed, since there is no special tools other than glue and shringe needed.
Today, I was primarily checking for the condensation (see another thread about water in the hulls) which has dried up, having left the port lids off for ventilation. Reaching inside, you can feel some foam that has dripped down inside the hull, but I have no problem with that if the decks are firm, and it saves drilling and repairing all those holes through the gelcoat.
Through the ports, you would be able to access the sides as well as the deck, and I see no reason it should not work just as well. I still maintain that the Gorilla Glue foam is just as strong as the original structure. There was no apparent distortion, or further separating the layers of glass, so I have high hopes that come Spring '06, that I should be able to have a safe and successful shake down cruise.
TnT