How to apply an epoxy sponge joint

Not so easy to apply properly © O. Chauvin

A cutaway joint is not so easy to make properly. Whether it's structural on the boat or simply intended to fill a corner. Here's how to do it without pain or mess.

A mitered joint is the filling of a concave corner with a filled resin. It ensures the cohesion of panels between them, but also avoids corners that are difficult to clean or maintain. It is commonly used on boats made of marine plywood or composite materials. A commercially available filled resin or epoxy filler can be used. Regardless of the product, the method of application remains the same.

Preparation of the support

The preparation begins with a careful sanding that allows to scratch the surfaces and to offer a good grip to the products. Choose a day when the temperature and humidity are within the range recommended by the product manufacturer.

Le ponçage, une étape nécessaire
Sanding, a necessary step

Degreasing

Product inserts are clear: A apply to a clean, dry, dust and grease free surface ! For a long-lasting result, don't neglect this step. Dust carefully and wipe the entire application area with a cloth soaked in acetone.

Dégraisser, ne serait-ce que les traces de doigt
Degrease, even if it's only fingerprints

The application material

Prepare products, mixing, application and cleaning materials. For small quantities, paper plates save a lot of cleanup. A set of spatulas, including a narrow one, will allow for easy application. Finally, don't skimp on the rags!

Prévoyez d'avoir tout le matériel à portée de main
Make sure you have all the materials on hand

A measured mixture

We used an epoxy coating that comes in tubes, whose contents are dosed in equal parts. It is easy to form two beads of equal length and then mix them. The base and the hardener are of different colors, which ensures a good homogeneity.

Avec des tubes, le dosage est facilité
With tubes, dosing is easy

Application and smoothing

Apply with a narrow spatula, or a tongue depressor that allows you to form the rounding in one motion. The Rubson spoon, or any other slightly hollow spoon, is a practical tool that allows you to smooth out but also to pick up the excess product. You can adjust the shape of the rounding by tilting the smoothing tool more or less.

On cherche à former tout en éliminant tout surplus
We seek to train while eliminating any surplus

Burr-free finish

To facilitate finishing, care should be taken to leave no burrs or excess thickness. The coating we used is fairly easy to sand, but this is not the case with silica-filled epoxy resins.

Application dans un cockpit en contreplaqué
Application in a plywood cockpit

Last step, the primer

To help with sanding, you can use a rounded wedge like a portion of a broom handle. After a new dusting and degreasing, it will remain to apply a primer, which will protect and ensure the sealing of the surface, while promoting the adhesion of paint.

Après primer, le joint-congé présente un bel aspect
After priming, the cut seam has a nice appearance
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