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Hi Frank, As you know, not all epoxies are created equal. "If you are making an electrical through-hull, the nipple method is more leak proof than either the disk or thread-o-let method. The nipple is filled with epoxy, and I can't see how that would leak." "Epoxy may make it difficult to change out a valve or fitting, and because it has a different rate of expansion/contraction than the associated parts, it may fail." I agree with your point of using something more flexible then a hard epoxy type product to seal threads, but epoxy in a nipple for potting an electrical thru-hull can leak depending on the design and mass of the different parts involved, along with temperature and depth of dive. But for the depths your likely to go to, you shouldn't have any trouble with your plan. Look at Dan H's potted electrical thru-hulls. They are some of the best I've seen. I wonder if there is a good slightly flexible alternative to epoxy for potting electrical thru-hulls, like Sika Flex or the like? Perhaps even put a layer of Sika Flex in the item to be potted, and then once that is cured pour in the epoxy. You can also machine in some grooves in the metal part to be potted to help the Sika Flex seal out water even better. This way the epoxy will act like a mini conical acrylic view port in a conical seat, sealed by a flexible sealant. Regards, Brent
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