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Old 01-17-2008
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Jeff_H Jeff_H is offline
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This is not all that unusual a problem. Cals, like many production boats of that era had plywood cored decks, especially near high load areas like a mast step or cockpit sole. This is both good news and bad. Plywood is strong and relatively easy to repair, but plywood is more prone to rot, and allows the rot to move more quickly than balsa coring.

The folks at Gougeon Brothers (mentioned above) and at MAS epoxy (my preferred epoxy for the kind of thing you are doing) are the best resource for this kind of project.

I am also concerned that you think that the through deck connectors are the source of your rot problems. If they were properly installed, with all of the holes potted and the fittings properly bedded, there is no way that these fittings could get rot into your deck. Beyond that, as a general rule, where possible, connectors such as these work best when installed in a vertical surface rather than a horizontal one.

Now then, before you open your 3K of eposxy supplies it probably makes sense to ask if this is the best way to spend your money. I liked your original idea that, you can take all of your new gear and transfer it to a bigger, better condition, better designed boat. That may actually be a better use of your money than spending 3K trying to piece back together a boat boat that has lot of problems and a total value all fixed up of less than $10K

Respectfully,
Jeff
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