Attaching the Deck and Hull (Electric Glue Gun / Tape Method)
Prepare both the deck and hull by sanding the edges smooth with a slight taper to the inside, favoring a good visual joint on the outside. This taper will get flooded with epoxy as you tape them together from the inside.
Fiberglass packing tape is used to temporally fasten the hull and deck together; 2 rolls of 60 yards by 3/4” are enough. Give the deck and hull a good washing to remove any blush so the packing tape will adhere well.
Attach fiberglass Tape
Use 2” or 1" fiberglass cloth tape and fasten it completely around the inside of the hull laying half it’s width below the edge. Fasten it with and electric glue gun, using a small dab of glue every 6” or so. Half of the tape's width now sticks up above the hull lip. This method is the only way to insure that glass is up in the bow and stern where you can't see.
Attach the Deck
Don’t be alarmed that your deck and hull no longer fit. They never do because of the strains of epoxy shrinkage. You’re going to be off ...sometimes your hull’s a little small or wide at a few areas. There’s plenty of flex to force it together or spread it open.
Beginning at the bow and stern, position them and tape them together. Work your way around, and tape the areas that fit the best first. Pull hard on the tape as you force the deck down tight to the hull. Push in any fiberglass that gets caught between the joint. This is truly the one time having an assistant is great. I have always done it myself and have resorted to laying the boat on its side on the floor and sitting on it to force a few stubborn areas together. Use a knife to wedge between the joint to leverage it open or closed if you need to. Use plenty of tape. Run a sealing line of tape down the entire joint on both sides when you’re finished.
Bond the bow and stern ends
Make a stick brush by taping the cut-off end of a 1 inch brush to a bent piece of metal which you tape to a 4 ft. length of strip.
Use long dish washing gloves and long sleeves for this operation. Mix about 8 oz. of epoxy and reach your hand into the front hatch and pour about half the cup as far as you can reach toward the lowered bow. Pour the rest along the glass tape toward the hatch opening. Lower your brush stick in and work it back and forth wetting out the glass tape and pushing the puddle of epoxy deep into the bow tip. You can view your progress from the cockpit opening. You can add more epoxy to the brush to wet out the area more thoroughly.
Now lower the stern, raise the bow and repeat the process. Here you can fit your head and arm into the rear hatch opening for a view. Wetting out the remaining stretch of tape is easy with the stick brush and by hand. This is one time you want to wet it out good. You want to fill the crack between the hull and deck joint.
Once the epoxy has cured, turn the boat over and do the other side. You’ll be surprised how easily this actually goes.