repairing crack on deck

eggman2001 · #1 (**permalink**) 08-23-2008

I've got a 3-inch long crack on my deck that goes completely through to the other side and I'm wondering. I've never repaired fiberglass before but I assume it's something like cutting out the cracked area and then filling it. Does anyone know of any good tutorials I can follow?

camaraderie · #2 (**permalink**) 08-24-2008

You'll find good tutorials on this site:
WEST SYSTEM Epoxy

maccauley123 · #3 (**permalink**) 08-24-2008

West System has great info and publishes a good book on it. I also use Vaitses Fiberglass Boat repair manual. Also Don Casey's This Old Boat.

Basically you are on the right track but make sure you put a really good bevel on either side. Gives a much larger surface area for the epoxy to bond to. Then just build it back up with fiberglass.

I am far from an expert so consult them.

eggman2001 · #4 (**permalink**) 08-26-2008

Great, thank you for the help.

mangomadness · #5 (**permalink**) 08-26-2008

Check out the blogs and links at the bottom of my blog(scroll down) for lots of pics and lessons learned. I add links that are relative to fiberglass repair/ painting when I find them.

jarcher · #6 (**permalink**) 09-29-2008

Quote:

Originally Posted by mangomadness

Check out the blogs and links at the bottom of my blog(scroll down) for lots of pics and lessons learned. I add links that are relative to fiberglass repair/ painting when I find them.

That's completely amazing! I had no idea that such restoration could be made. It never even occurred to me that so many big holes could actually be repaired and filled.

Does doing that add much weight to the hull? Is it possible to do that and apply gel coat instead of painting?

That was amazing work!

NOLAsailing · #7 (**permalink**) 09-30-2008

Rob (mangomadness) did do an amazing job. Now if he would just sail over to New Orleans for a little one design racing...

Before you fix the crack, you need to fix the cause of the crack. Assuming this isn't the result of a collision, there's likely another structural weakness. Is the deck cored?

mangomadness · #8 (**permalink**) 09-30-2008

I would have to re-due alot of mods to be able to sail one design again. Plus the panama canal route from Hawaii might be above budget.

mangomadness · #9 (**permalink**) 09-30-2008

Quote:

Originally Posted by jarcher

That's completely amazing! I had no idea that such restoration could be made. It never even occurred to me that so many big holes could actually be repaired and filled.

Does doing that add much weight to the hull? Is it possible to do that and apply gel coat instead of painting?

That was amazing work!

I don't think it added amy weight since I used balsa to recore. If anything I reduced weight with the removal of wet core.

My nonskid pattern in my gel coat was so worn it was nonexistant. I made the decision to paint. If your gelcoat is in good condition I would try to re gelcoat even though it would be impossible to match the color perfectly. Remember once you paint, you're commiting to always re-paint.

hellosailor · #10 (**permalink**) 09-30-2008

Eggman, you might want to call West System's tech department and discuss the crack with them. (You pay for the call, the support is free, even if you haven't bought anything yet.)

I would be concerned that the crack means the deck was really stressed or impacted, and there is damage to the fiberglass in a larger area around it, i.e. extending for several inches on either side of the crack. Maybe it is ignorable--but they might suggest cutting it back and bedding in a new section, rather than gambling on it.

It can look perfectly good on the outside--but the glass fibers may be broken inside.