Epoxy fill of scupper holes using PVC core/pilot hole worked out well - mismatch between original hole & drilled hole at bottom was about 1/32", easily filled with 5200. Would have probably been better if I had used a flat wood drill bit with pilot feature instead of conventional bit which tended to walk.
Epoxy Fill: You will probably discover that the wood block is no longer sealed to the hull, so if you try filling it with plain epoxy as I did, it just runs out at the bottom. Next try with epoxy thickened to about apple sauce consistency worked well. I used MAS slow cure hardener & chilled it & resin in fridge first; otherwise it wants to kick off pretty fast once you pour it in caulk tube! Ended up using 3 caulk tubes, but wasted one due to sealing problem mentioned above. Will try to post some photos.
Brass Tube Installation: (Ordered 1" ID x 6" long brass tubes from Boat Owners Warehouse, about $6 ea., got them overnight) The hole came out about 1/16" oversize due to drill walk, so filled it with 5200 as I slid tube in from top. Installed drain plug in top of tube first for leverage. Need to flare bottom of tube right away to keep 5200 from running out bottom because it's pretty slow to cure. Used a threaded rod, with nuts, washers and a 1/2" drive socket to get the flare started.
Results: After letting the 5200 cure for about 5 days, took the boat out for about 6 hrs, 4 of which was at anchor, bilge pump OFF for entire time. Pulled boat out, pulled bilge plug - it was dry, didn't leak a drop!
Tried posting photos; Need to edit photos to reduce size.
http://s188.photobucket.com/albums/z...scupper%20fix/