Never done this before & have some ideas. I have an Kona jet with a BBC that had the old exhaust logs thru the transom. Going with Stainless Marine with risers over the transom. I think the holes are around 2 1/2". Any suggestions ?

wood or foam Plug ......fiberglass ..cloth fiberglass......Gelcoat ...

sounds ez .....

Thats what I was thinking. I have a nice piece of micro-lam that will work

You have to grind a bevel in the glass on the side of the drive opening. This way the glass has something to grap onto. I can not remember what the cut back is per inch of glass thickness but if I was to guess you will be grinding a slope away from the drive about 3" at leaste. Depends on how handy you are if you want to tackle this or not. It is what I would call a large job.

Jon

There are also fancy plugs available to cover the holes when switching to OT exhaust.
http://www.cpperformance.com/detail.aspx?ID=392

I hear ya, a 2" repair will probably be spead/feathered to about a 8" area. Should'nt be a big deal. The only PIA will be the paint which is a metal flake from the 70's. I did some hull repairs a few years back. Base coat...clear w/the metal flake..and ALOT of clear on top. Not to mention the wet sanding.

Thought about that at first but decided to make it right. Thanks for the input.
Stan