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Old 02-14-2010
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Dynel over Ply

I just bought a new boat and sold the old one. The new boat has a few minor soft spots in the deck. The deck is plywood with timber reinforcements. This was bolted to the hull and sheathed in a layer of Dynel. Has anyone done repairs to deck like this? I need to somehow replace small sections of the ply and sheath with another layer of Dynel. Any tips here?

Currently the plan is to use a dremel or grinder to dig out the rotten ply from underneath. Then fabricate a new piece to fit and coat it in epoxy. Slather the upper face with some thickened epoxy and apply pressure to the bottom with a jack or a wedge, making sure to have a drop cloth ready for all of the rotten core bits and dripping, thickened epoxy. Then I would scarf the new scab in with glass. Any tips on upside down glassing?

After the new core is in I would grind down to bare dynel from above and laminate a new patch over the failed area.

This would be one technique to do it.

The other idea I was thinking of would be to cut a hole through the deck at a tapered angle, leaving the end grain of the ply facing up on all sides of the hole. Then I would drop in a new sealed piece of ply, and laminate dynel over that.

Another alternative to scarfing in the new core with glass would be to build a timber frame underneath, and rely on that as structure, but still add new Dynel on deck for abrasion resistance...

Has anyone on here replaced Dynel over ply/timber decks?
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Old 02-14-2010
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Lots of threads here on deck repairs cPanel®
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Old 02-15-2010
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So far the one soft plywood spot on the current project i have dug out ended up 1' wide and 4' long and only stoped there becasue the wood ended

And while most of the plys were not rotted they were NOT plywood anymore
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Old 10-17-2010
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Personally between me and you, find a carpenter. If you don't, then you'll end up spending valuable time doing a job that isn't so great. I had a similar problem on my whaler, and let's just say my date found out about my shoty work via a broken ankle.
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