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Old 05-15-2006
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duffer1960 duffer1960 is offline
Catalina 38 Avantura
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What's the best way to epoxy in plywood?

First, the basics:
The wood underneath the cockpit sole of my sailboat has rotted out. I was able to access the area from underneath and remove all of the rotten wood. I plan on epoxying in new marine grade plywood as a replacement. The area to be replaced is a basic "T" shape about 3 feet long by three feet wide with the "arms" and "body" of the "T" being about one and a half feet wide. My plan is to cut a single sheet to fit this area and to epoxy it in.
Now, the questions:
Is it best to use one solid piece of plywood, if possible, which I think it will be, or to epoxy smaller sections in at a time?
If a single piece is used, how do you get the air out of the epoxy from between the existing fiberglass and the new sheet? Should I drill some holes through the plywood before epoxying it in place just for this reason (to give any air pockets somewhere to get squeezed out)? Or is this why I should epoxy in small sections?
About how thick should I mix the epoxy with filler, and how thick should I spread it on? Do I spread it on both surfaces or just one (I know to wet all surfaces with unthickened epoxy beforehand)? Do I spread it on with a putty knife, bondo spreader, or one of those spreaders you use for grout or floor adhesive?
Any other advice is appreciated.
Russ Duff
Catalina 38, Hull #112
Lake Erie
Grosse Ile, Michigan
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