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  #71  
Old 05-23-2014
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Re: Cored deck soft spot repair

So, I am almost done my core project, but am torn between laying new fiberglass over the core, or gluing the skin.

So far, I have laid a sheet of glass, glued the core down and was going to lay one more layer of glass. I was then going to glue the deck laminate down.

Plan B is to lay new glass and see if I can sand smooth. I am a bit nervous about this, but feel pretty good with the way the first half has went.

Questions:
- If I glue the skin down to new glass, do you think I still need to tape the seams with new glass as well?
- If I lay new glass, how much overlap would I need to reinforce properly.





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  #72  
Old 05-23-2014
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Re: Cored deck soft spot repair

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  #73  
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Re: Cored deck soft spot repair




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  #74  
Old 05-23-2014
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Re: Cored deck soft spot repair

Quinn99,

The answer always is: "It depends."
The basic rule is to fair out from your hole/crack/seam in a 12:1 width; so for a 1" deep hole you would fair out 12" and replace with new laminate.

I did my port side deck recore last year by re-gluing the top skin down. I did my stbd side deck recore this spring and re-laid new laminate for the top skin, which I think works better leaving no seam to fill.

The cloth that made building up the new laminate easy was a biaxial cloth I got from fiberglasssite.com - but I had to buy something like 10 yards of material, which is more than I need. I think that this biaxial cloth builds up close to 1/16" per layer which is a lot.

Here are some pics of my first re-core attempt where I re-used the top skin: 2013, May 2nd. Re-core work party. | Odalisque

PS: my port deck looks a lot like your pictures. I'm moving on to painting and trying to finish up this job.
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Old 06-03-2014
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Re: Cored deck soft spot repair

Caleb - For your port side re-core where you re-glued the skin, do you think it would have been easier to bevel before you glued the skin down, or was it easy enough to do after?

I am still considering laminating the skin down as my port side is not even. I have leveled it as best I can, but think that a thickened epoxy with the skin would help smooth the bond and ensure it is flat and even surface. I am not confidant that I could laminate new glass and get the same result.

My starboard side is a different story as it is level and I would attempt attempt to glass it over. May try both???
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Old 06-04-2014
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Re: Cored deck soft spot repair

Quote:
Originally Posted by Quinn99 View Post
Caleb - For your port side re-core where you re-glued the skin, do you think it would have been easier to bevel before you glued the skin down, or was it easy enough to do after?

I am still considering laminating the skin down as my port side is not even. I have leveled it as best I can, but think that a thickened epoxy with the skin would help smooth the bond and ensure it is flat and even surface. I am not confidant that I could laminate new glass and get the same result.

My starboard side is a different story as it is level and I would attempt attempt to glass it over. May try both???
Won't hurt to try either way. I couldn't reuse the top skins when I recored my decks so I had to laminate new glass on about 75% of my boat. I can't even tell where the repairs were done with my eyes at deck level, and I'm pretty picky! When I did that project it was my first time working with epoxy and fiberglass too.


Getting the laminate or old skin level is a big help, but sanding and fairing can cover up a whooooole bunch of "oops".
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Old 06-04-2014
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Re: Cored deck soft spot repair

QUINN99,

Looking good, I will be attempting this same type core project on my Alberg 30 this fall. Keep up the good work
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Old 06-04-2014
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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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  #79  
Old 07-31-2014
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Re: Cored deck soft spot repair

Well, "almost done" was a bit of a stretch?! Finally there is an end in site. Unfortunately, work, rain and a two year old have slowed the process. Here is a few pics of the final stages.







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Re: Cored deck soft spot repair

Now, the question of the day is "thoughts on finish"? I was planning on using either a quikGrip or non slip with sand. Anyone have input on either of these. I also have one fellow encouraging me to redo the non slip pattern with a wax mould. I am open but want to get this boy sail worthy soon before the season ends! Hoping to do a two week trip in three weeks


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