Hey guys thanks for persuading me to keep the scuppers - I think...The scuppers will remain. The epoxy is setting up in one scupper hole as we speak.
My process began with caving in the bottom flange a little and pushing them up into the cockpit.
Used a piece of PVC to tap them out. Port wood was dry and looked good, starboard was wet and pickled. That's definitely where the water ingress occurred, of course I knew that from watching the stream flow along the string when I'd open the port stern locker.
Straightened out a 1" brass pipe brush and cleaned out the surface rot and whatever sealant remained in the cylinder. Wasn't much of that, even on the brass tubes.
Sprayed the tubes with alcohol a few times through the week to try to eliminate any moisture in the wood. Hit it again with the brush, and then taped off the bottom. I straightened out an old weenie roller and soaked the roller pad in some acetone to clean and prep the hole best I could for better epoxy bond - at least to the resin.
I taped off the bottom and mixed up the epoxy. Foolishly mixed up enough epoxy for both holes. I wanted to pour in the epoxy after letting it warm up a bit concerned it would flow into the bilge if it was to thin. My plan was to pour in the epoxy and use a nitrile glove over a piece of 3/4" pvc to displace the epoxy and force it up the walls evenly leaving a cavity in the middle.
Should have lubed the glove. As it set up I tore the glove trying to get it out (knucklehead) leaving a glob of epoxy in the bottom. Now I'll drill it out. Should have just filled the whole thing and planned on drilling anyway. But dang, it was tough to find a 1" bit in this town. Settled for 1-1/64". Give me a little space for the sealer.
I may try the displacement technique again tomorrow. Maybe put some vaseline on a dowel this time...