Join Date: Aug 2006
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Re: Leaky Genoa track caused wet core
I agree with some of the other posts. You already made the cut so why not go a little wider, pull out the old wood and install new wood? For cutting the existing fiberglass you might want to consider a battery trim skill saw with a 7.5 inch blade diameter set to a quarter-inch cut depth. I have also used my makita 4-inch trim saw which easily cuts the existing glass deck, just don't cut to deep! Remove the old wood and replace. I have used the lower layer of fiberglass for supporting the new materials. I have also used screws to temporarily clamp the wood in place, after the resin or epoxy cures I remove the screws and then fill/coat the holes with epoxy (both thickened and unthickened). If the screws penetrate the headliner, tape the hole (I prefer gorilla tape) to insure no leaks into the cabin area, then repair the hole when finished. After the wood is set, use fiberglass and fair into the remaining decking. You will want to fair into the original deck to prevent cracks at the repair joint(s) in the future. Once the deck is complete and you are ready to reinstall the g-track, oversive the holes for the bolt and fill with thickened epoxy (collidial silica to peanut butter consistency). (Note: use gorilla tape or similar on the underside of the hole to support the epoxy until it is cured) Then drill a hole for the g track bolts in the center of the thickened epoxy. This will help to insure minimal water penetration back into the deck. You should also consider using 1/16th thick butyl tape under the track. Also on the underside of the bolt head (google Maine Sail website/Musings with Maine Sail) I found the west system website and information very helpful, too.
Last edited by ambianceack; 03-29-2013 at 06:48 AM.