Join Date: Jun 2000
Location: CT/ Long Island Sound
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I like using a dremel or similar bitted tool. It enables you to get closer to the edges and to do a neater job, especially around scuppers and the like. A bigger tool will create problems getting in there and seeing what you are doing. Since it's cored, you only want to go through the top layer anyway. A smaller tool will give you better depth control as well. You only need to go through the top 1/8" (maybe) of fiberglass. Once you've pried that off, the rotted core should come up with a screwdriver or putty knife. You can bed new core on the old inside layer, and then layer in the new cockpit floor layer. (You probably already know this.) The extra plywood support piece they added in probably won't be necessary once the repair is made and everything is stuck back together properly. We repaired our cabin top from the inside, and getting the resin, core and fiberglass to stay UP was a major Chinese fire drill. Working with gravity is a good idea when you can do it. To avoid crazing or point failure later, it will probably be a good idea to grind down the edge along where you cut so as to have better adhesion and to increase the contact area between the new and old fiberglass.