Looking for HDS Leak repair advice

[DataCowboy]

We dumped our 98' Sunsetter direct drive in the lake for the first time last weekend and were lucky enough to be a victim of the HDS leak.  Prior to this I had no idea what an HDS was or how common the issue seems to be.  I have read through a variety of previous topics with some great ideas and fixes, however, I'm looking for some answers on a few things before I start the repair.  

Plan - re-fiberglass the perimeter of the box: 

1. Test to confirm it is an HDS leak - Complete 
   1. Installed plugs
   2. Fill bilges with water in driveway
   3. Water leaked from where the prop shaft enters the hull
2. Remove lid - Complete
   1. Dry the inside of the hds
   2. Re-fill bilges with water to test again and found out it is leaking in the back of the box 
3. Clean the surface (The previous owner had a dealer (Non-Malibu) repair the HDS and it looks like they just siliconed the heck out of it) 
   1. Dremel with brush bits, Plastic bristle brush, Acetone
4. Fiberglass
   1. West System 105,  2" and 4" Cloth (3-4 layers) 

Questions:

1. How did Malibu attach the HDS from the factory?  If they used an adhesive on the seam, will that prevent the fiberglass from adhering? Should I grind that down and then glass? 
2. What product to seal the strut bolts? 3M 4200?
3. What product to seal the lid?  Marine grade silicone? 

Edited May 15, 2020 by DataCowboy
Clarifications

[Eagleboy99]

Forget the HDS and just do a proper shaft log.  http://www.everglass.org/shaftlog.htm  That HDS was likely Malibu's worst mistake ever.  Well, maybe putting all those non-replacemeble touchscreens might out touch it at the wall.

[justgary]

On 5/15/2020 at 3:01 PM, DataCowboy said:

We dumped our 98' Sunsetter direct drive in the lake for the first time last weekend and were lucky enough to be a victim of the HDS leak.  Prior to this I had no idea what an HDS was or how common the issue seems to be.  I have read through a variety of previous topics with some great ideas and fixes, however, I'm looking for some answers on a few things before I start the repair.  

Plan - re-fiberglass the perimeter of the box: 

1. Test to confirm it is an HDS leak - Complete 
   1. Installed plugs
   2. Fill bilges with water in driveway
   3. Water leaked from where the prop shaft enters the hull
2. Remove lid - Complete
   1. Dry the inside of the hds
   2. Re-fill bilges with water to test again and found out it is leaking in the back of the box 
3. Clean the surface (The previous owner had a dealer (Non-Malibu) repair the HDS and it looks like they just siliconed the heck out of it) 
   1. Dremel with brush bits, Plastic bristle brush, Acetone
4. Fiberglass
   1. West System 105,  2" and 4" Cloth (3-4 layers) 

Questions:

1. How did Malibu attach the HDS from the factory?  If they used an adhesive on the seam, will that prevent the fiberglass from adhering? Should I grind that down and then glass? 
2. What product to seal the strut bolts? 3M 4200?
3. What product to seal the lid?  Marine grade silicone? 

I like your plan.  If you get everything clean and wipe it with acetone, you should not have any problems with adhesion.

Yes, 4200 for the strut.  I would go ahead and use the 4200 on the HDS lid as well.

[Lampkamm]

May I ask how, after removing the screws, you separated the HDS top cover from the box? I see an gasket sealant in your pictures.