Deck void

[Sixbrothers]

I have removed the deck hardware for on of my stays (leaking). It consist of metal plates top and bottom with two bolts running through the cored deck. There was water in the core material (Klegcell closed-cell polyvinyl). I pulled out most of the wet mushy material about 3" around where the bolt holes and I'm letting it dry. The fiberglass panels on top and bottom are solid and show no sign of what was going on inbetween.

I was planning on filling the void and redrilling the bolt holes. What kind of material would be best for filling this void?

[sailingdog]

I would fill the area with thickened epoxy, filled with either high-density or collodial silica filler. This is for three reasons. First, the epoxy will prevent water intrusion into the core from this area in the future—helping prevent delamination, core breakdown and a bunch of other bad stuff from occuring. Second, the thickened epoxy will also bear the compressive loads exerted by the stay chainplates better than would a foam or wood core replacement. Third, using epoxy to fill the void is probably the least difficult and simplest way to repair said void.

If you want to use a core material to fill the void, I would go with Marine Plywood, and then pot the holes properly. However, this would require cutting away the skin on one side to insert the plywood replacement core in place.

[Sixbrothers]

Thank you for your advice. I will go the thickened epoxy route. Is this something you have to mix up yourself or can you buy it premixed?

Do you recommend any particular brands?

[Freesail99]

I like mas epoxy others like West. Yes you need to mix it yourself, and you may want to use a counter sink when you drill out the holes you filled with epoxy. It will aid in stopping leaks.

[sailingdog]

You can use Mas, West or System Three epoxy to do the job. I've used System Three and West mostly. You should probably wear a dust mask at a minimum when working with collodial silica, since it is not good to inhale the silica particles—causes silicosis in the lungs—and the stuff stays airborne a long time.

The tip about counter-sinking the fastener holes slightly is a very good one, and one I've been using a long time. It gives the sealant a space to form an "o-ring" of sorts when you clamp down on the bolts.

[Sixbrothers]

Thanks for all your advice. I will be doing this this weekend if it has dried enough.