Join Date: Nov 2008
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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?