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Old 10-28-2010
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If the deck is cored with plywood and you are only replacing some core I would stick with plywood. For a total recore I would switch to balsa.

At the edges where the core tapers I would shape the plywood for a close fit and the thickened epoxy will fill in the gaps. If it is not shaped to fit you will use more epoxy and plywood is less expensive than epoxy.

I wouldn't worry about hard spots. Many manufacturers replace core with solid glass for hardware attachment. As long as the skin is strong enough it is not an issue.

Here's a link to a recoring project on Glissando, Tim Lackey's own boat. A lot of good information from an expert at this - he restores boats for a living and does a great job.
Pearson Triton #381 Glissando | Deck Recore Project
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