You have two options for repairing your extension. The preferred and easier method requires a heat gun, but the job can be done without one. The job is quite simple you just need a few supplies, and this step by step instruction. We recommend printing it off so it is at hand during the repair.
STEP 1. GATHER MATERIALS
You will need:
- Fatso or Fatso Jr. extension
- Tiller extension repair kit
- Heat gun
- A broomstick or metal rod that will fit inside and slightly longer then the extension
- Some west system, system 3 or other boat builders epoxy
- Electrical tape
- Gloves, Dixie cup, and popsicle stick, (supplies to mix the epoxy)
- Safety glasses
STEP 2. PULL OFF END CAP AND INSERT DOWEL/ROD
Take off the end cap, insert the rod and flip the whole thing upside down and let the rod rest on the floor, with the universal up in the air.
STEP 3. HEAT WITH HEAT GUN
You’re going to heat up the last two inches of the extension with the heat gun rotating the extension the whole time. This will soften the black casting material that the universal rotates in. After a couple of minutes of constant heating pop out the plug.
STEP 3. WITHOUT HEAT GUN
If you don’t have access to a heat gun, you can take a hack saw and saw off the black epoxy and the universal flush with the end of the extension and drill out the remaining uni and epoxy with a ½” drill bit. This method will leave quite a bit of epoxy remaining which will need to be removed so the new repair kit can be installed. The goal is to remove the epoxy from the carbon fiber tube. Remember to test fit the new piece before mixing the epoxy!
NOTE: Some people have had success with putting the end of the extension into boiling water to heat it for a few minutes before trying to pop out the plug.
STEP 4. POP OUT PLUG
Slide the extension up in the air a few feet and slam it down on the rod/dowel. DON’T be shy, if nothing happens after a couple of really solid WHACKS, heat it some more and try again. You should wear your safety glasses.
STEP 5. CLEAN TUBE
Once the universal is out of the extension clean out any visible remaining epoxy. You can use a file or a scraper but BE CAREFUL not to damage the carbon fiber laminate.
STEP 6. MIX EPOXY
Once the inside of the extension is clean it is just a simple matter of mixing some new epoxy and spreading it on the inside of the tube and the outside of the repair kit. Then inserting the new piece into the extension.
STEP 7. TAPE IN PLUG
Tape the end of the extension to hold the kit in place as the epoxy hardens. The tape will also ensure that any epoxy doesn’t leak out.
STEP 8. STAND TO CURE
Stand the extension right side up and set it aside to cure. This will allow the epoxy to run down on the top of the kit and glue it in tight. The tape will keep it from leaking. Let the epoxy cure, put the end cap on and remove the tape.