Senior Moment Member
Join Date: Jun 2011
Location: West Vancouver B.C.
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Re: Recore Entire Deck
I did about 50 sq. ft. of recoring on my boat last summer. Do it from above - don't even consider doing it from underneath - gravity is your friend from above and your enemy below.
Do it in sections and reuse the top skin if you can although for a job as big as yours it may not be worth the extra grinding etc. - you'll have to Kiwigrip it or use another product no matter what.
Find an industrial type source for your epoxy & other products - West at retail is twice what I paid. The thickeners are 10X the price of industrial suppliers. You'll need a lot of everything so the savings are large.
Cut the top skin off, clean everything up well and sand the top of the inner skin. Squeegee on a thin coat of thickened epoxy to level things up then sand it when cured. Cut your balsa to fit the area you will be working on. When fitted well, roll on resin on the "down" side of it. Open all the cut lines and coat them as well. Roll on resin into the area you will be placing it and fit it. Cover with poly plastic and weight it with sandbags or plastic jugs of water to clamp it down. When cured, inject or squeegee thickened epoxy into any seams that are open at all - around the perimeter of the core especially. When it's all well cured, sand it lightly to remove the bumps (balsa is soft so not too hard with the sanding) and you can move on to the top skin replacement - either new fabric or putting the old skins back. Roll on resin first to seal the core. When it's cured, lightly sand and then do the skin.
It's a pretty simple job - no special skills required, just repetitive, messy and itchy - work neatly to minimize the sanding & grinding of glass. Use gloves at ALL times - get a box of quality latex gloves before you start. Cheap ones fall apart.
I, myself, personally intend to continue being outspoken and opinionated, intolerant of all fanatics, fools and ignoramuses, deeply suspicious of all those who have "found the answer" and on my bad days, downright rude.