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OK - I put another hour into the project and have some discoveries. First, the inner layer where the majority of the problem lies is just a single layer of fiberglass mat. Fiberglass gets much thicker at the edges.
I decided to cut away the entire thin area that was easy to peel away. Now I have edges toward bow and stern where the ceiling fiberglass and inner plywood are as-one, a laminated assembly.
The next discovery was a seam in the plywood. The bad piece is the one on the outside edge of the boat (since water drains that way). The piece toward the center has not rotted and is just slightly damp on the edge.
Now, I've got the wet wood removed, and have a fairly sloppy shape to fit, with one edge that is straight.
I am wondering how I should fill the core. If I use plywood, which I have enough from the original ceiling carpet backing, I'll have a difficult time getting all the edges to fit well. The surface is curved in multiple ways.
Alternatively, I have a bunch of scrap red oak that I can shape to size, in strips. Red oak is not a good boating wood, but it seems to me if any wood gets wet in this way, it is done; the water is trapped, so penetrations must be sealed well.
I was thinking the oak would perform best because of its stiffness. And if I made two layers of 3/16" thick each, I could run grain perpendicular. This would allow me to tuck some of the pieces into a few voids where wood was removed but inner fiberglass is still in place.
I have an epoxy adhesive to apply as a bedding to bond to the top fiberglass, and clamp. Then I was thinking liquid nails between oak. Then re-glass bottom fiberglass.
Too McGuyver? I'm open to suggestions.
Last edited by brainiac; 05-04-2010 at 11:27 PM.