This is a great thread, which I have been following to some degree as I prepare for tasks with my boat project. Today, I cut out the hole for a deck hatch install expecting to see something like the photos included on the link at the start of this thread to the 'photo how to' on preventing boat through deck rot. However, when I finished cutting the hole, this is what I found. Not a balsa or ply core but a 'hollow-core' build. So, is this normal?
When I look close, I can see about 1mm of gel-coat, fibre glass, then about 12mm of cavity, followed by more fibreglass and then the inside 1mm of what I presume is gel-coat. (yes, metric, it's all I know
) The total deck width is 25mm.
The deck hatch I purchased has an aluminium frame with about 12 holes that I still need to drill. The last photo shows what the previous owner did at the pop top, so I was thinking of inserting strips of timber into the cavity, sealing it with epoxy resin in some fashion, and when its cured, following the process described on page one of this thread.
Any comments or tips before I botch it all up??? Should I use ply or balsa or something else? What is a good way to seal it, do I coat it with epoxy before I insert the timber strips or after?
It was quite a moment when you first cut into your deck with a jigsaw!!!!