Join Date: Mar 2006
Location: New England
Thanked 14 Times in 12 Posts
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I really don't recommend drilling holes and injecting thickened epoxy, since it really doesn't "repair" the area and makes doing a proper repair much more difficult afterwards.
I also don't recommend doing a core replacement from the interior, as then it is far more difficult to get a solid layup of the replacement core and interior skin, since gravity is working against you. It will generally also take much longer to do it from beneath.
Chances are very likely that the water intrusion was caused by the mast step fasteners. I would destep the mast, cut the deck's top laminate away and then remove the core. Laying in a new core of Baltek ContourKore or Divinylcell foam is relatively simple. I'd point out that instead of trying to re-use the previous outer laminate, it is generally simpler and far more successful to lay down new fiberglass.
The surface can be easily be made non-skid via painting, or applying a non-skid specific coating like Durabak or Kiwigrip.
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You know what the first rule of sailing is? ...Love. You can learn all the math in the 'verse, but you take
a boat to the sea you don't love, she'll shake you off just as sure as the turning of the worlds. Love keeps
her going when she oughta fall down, tells you she's hurting 'fore she keens. Makes her a home.
—Cpt. Mal Reynolds, Serenity (edited)
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