Original black tank removal, starting on the new tank top

Cut the top off the old tank to use for a pattern

Clearance for shower trap

drilled holes to mark features

using a stainless bowl to form shower trap clearance

heat melts foam

blocks set depth

used a wire wheel to clean the foam off the bowl bottom after it cooled

Stripped torsion bar adjusting bolt

One side of the adjusting bolts stripped while adjusting height. Fortunately I had a longer bolt from Applied GMC in my spares. The bolt is what stripped and the nut while not the best will live on. A tap cleaned up the the threads in the nut pretty well. I did shorten the new bolt to match the original.

Tank clamps

                                         Packing tape for release

                Level setup

            Three layer of 9.5 OZ glass in this layup

                One side done

                    Clamps complete and cleaned up

Black tank level sender and drain

                         West epoxy with 405 adhesive filler

                                            Cup to keep flange centered

                           Two layers glass outside

                                  Test fit sender and valve

Fiberglass tank trim and popping the plug.

                Cutoff wheel on a grinder trims pretty quick

Foam sheets that were the plug came unglued and separated. Compressed air from a blow gun helped pop the plug out of the tank.

Core bond

                                         Marine plywood core

                                                          Taped off

                 Left weighted two days, peeled tape after a few hours.                         Bonded with West 105/206 epoxy and 405 filler.

             Filled the score with West 105/206 and 405 filler

                                        Ready for final layup

                                        Three more layers of  8.5 oz 7725 cloth

West epoxy tool clean up with white vinegar and then soap and water

Foam plug mold

                 Glued and weighted down

    Hot wire slides better on smooth surface, wrapping template edge with aluminum cut from house siding.

                     Edge wrapped for a smooth slide

                         Hot wire cut

                     Template for side cut out

        Slope 1-3/4" front to outlet and 1-1/4" sides to outlet

                             Core and support layout. Core scored halfway through.

Sides covered with packing tape, top 4 mil polyurethane film. Heating the poly took the wrinkles out after it cooled. Heating to get it to shrink and take care of wrinkles was a total guess method but it worked.

              Ready to go.....

                      West System epoxy.......

                First layer 1.5 oz cloth from
                      http://www.fiberglasssite.com/10-os-boating-cloth-50/
                 Next 3 layers 8.5 oz style 7725 cloth from
                      http://www.uscomposites.com/cloth.html
                 More layers to come after the core is bonded

Angle form for clamps