Originally Posted by jonp
Would be interesting to post a few images to the manufacturer and find if they are willing to help in cost and explain how it may of happened. The last thing any manufacturers want is customers not happy with their product or service on social media.
OP says it's had a previous repair so unless it was under warranty I can't see the manufacturer getting involved.
Be of interest as to how the previous repair was carried out, who repaired it & why.
Whilst many of the internet 'how tos' show repairs just being done from outside I'd want to access from inside to V the crack and repair properly.
There's a 'how to' here for repairing a foamed hull from the outside.
My own dory had a crack around 12" long which I was aware of when I bought it caused by impact & I cut a hole in the deck to access from above. Meant I could check for water in the foam in the area - it was bone dry - & do a proper repair. I cut the hole using a jigsaw set at a 45deg angle so the outside edge of the removed bit was wider then the inner (tapered) & it's easy to put this plug back in by lining the cut with fibreglass for a neat & strong repair. I also ground the crack on the outside of the hull meaning the inside & out repair fibreglass was bonded through. Outside then final filled with gelcoat, flatted & polished.