I have removed frozen through-hull fittings by cutting the flange nut with a
4" grinder with a cutoff wheel. Make 2 or three vertical cuts to separate
the nut. You may want to use your larger holesaw if you applied enough heat
to the flange to affect the fiberglass. There is little difference to fill a
1+1/2" hole as compared to a 2" hole.

John


"Ed Edelenbos" wrote in message
t...
"Jim Conlin" wrote in message
...
Brute force is called for- a hole saw or a small grinder. In either
case,
attack the outer flange.

Hole saw and/or belt sander (with a light touch)/ or grinder. Some amount
of beveling/fairing is going to be required to repair the hole anyway so
the grinder would probably be my 1st choice.

Ed



wrote in message
oups.com...
Hi,

I have a Cheoy Lee clipper. The prior owner plugged two of the thru
hulls that were used for the head. I want to remove these thru hulls
and glass and fair the hulls. My boat is on the hard right now. They
both are very old, and seized bronze seacocks manufactured 30 years
ago, one used for water intake, the other for waste discharge. The sea
cocks are completely corroded and seized. The outer flange is 1 3/4".
I've tried heat, liquid wrench, wood/hammer, etc. Since I have to
glass and fair the original holes, is there any downside to me taking a
hole saw and drilling a hole 2" and remove the thru hull in about 2
minutes instead of the hours and frustration that I have invested in
the project thus far?