Join Date: Aug 2000
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Re: Cored deck soft spot repair
I've done it both ways, and I prefer the new skin approach. I found that re-using the existing skin would have been more work than to laminate new cloth in place.
*One of the issues that you may run into reusing the existing skin is that you now have to bevel both the existing glass on the deck and the skin you are putting back in place in order to get your goal of 12:1 bevel for tape. The problem with bevels is that to do it efficiently, you generally use an angle grinder with 24 or 36 grit. It goes fast with this setup, but grinding bevels is a horrible, messy job unless you have access to a nice dustless grinder. I looked into them and they were pricey, if you can rent one, do so. I couldn't and ended up grinding bevels on roughly 120 linear feet of deck. If I had decided to re-use the skin, that figure would have been more than double. So for that reason alone it may be worth it to laminate new glass in place.
*Second issue is that when you get to the point of installing your old skin (after beveling and sanding the bottom side), laying it down and getting it to properly adhere to the new core can be unknown just by plopping it on and weighting it down. To be absolutely sure you have good contact between new core and old skin, you'd want to drill a pattern of holes in the old skin so that when you lay it onto the new core with epoxy, you get epoxy squeezing out the holes. Otherwise you can get bubbles of air under the skin that are trapped and prevent a good layup. This makes a lot of finish work required and all but negates any benefits of re-using the old skin.
Laminating with 2-4 layers of a 1708 biaxial fabric is not difficult and you'll be sure your layup is good. It will cost a little more because you'll need additional epoxy, and you'll have to purchase cloth and a bit of fairing compound.
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