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Go Back   SailNet Community > On Board > Gear & Maintenance > Deck Core replacement
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Thread: Deck Core replacement Reply to Thread
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Topic Review (Newest First)
03-03-2009 10:12 AM
zz4gta I have two peices in place now. I do have photos but won't be able to upload them until tomorrow. I'll be down this weekend to continue the work. I may only repair about a foot in front of the chain plates this season, and complete the work next winter. We'll see how this weekend goes.
02-28-2009 10:21 AM
Gary M I have done this on fairly small sections, no more than maybe a foot square. I used wax paper over 1/4" plywood propped up with flexible wooden pieces to first hold the coring in place then the two layers of glass. I will be doing 4 more small spots as soon as it is warm enough.

Worked fine, no real issues but I would be nervous about a large area. Start small and see how it goes.

Good Luck
Gary
02-28-2009 03:18 AM
Myblueheaven
core repair photos???? please post your progress

Please take images and post em here of the process. I (we) would like to see how this works out. I need to do the same.

thanks, Chris
(myblueheaven@att.net)
01-23-2009 12:37 PM
idontwantanaccount
what else?

Buy the dispenser pumps for the epoxy--well worth the cost. Also, I have always thought West episize fiberglass was overpriced, its much cheaper to buy a few feet off of a roll and to cut your own strips. Just make sure the cloth (esp. mat or cloth/mat composites) are compatible with epoxy. Last time I think I bought cloth from raka, but there are numerous sources if you search for them.
01-23-2009 11:39 AM
zz4gta One last question on materials, I'm looking at picking up the following and wanted to know what else I was missing. Please feel free to chime in.


750361
Epoxy Resin 105-B 10.3 Lbs. $68.99 $68.99
This item is on sale. - Our Regular Price: $74.99 - You are saving: $6.00

--------------------------------------------------------------------------------

750364
Fast Hardener 205-B 2.3 Lbs. $30.99 $30.99

--------------------------------------------------------------------------------

750408
Colloidal Silica 406-7 0.8 Lbs. $17.99 $17.99

--------------------------------------------------------------------------------

751507
Episize 9oz. Glass Tape 733 4.4 Lbs. $90.99 $90.99

--------------------------------------------------------------------------------

Subtotal: $208.96
01-16-2009 10:12 AM
popeyeforearm Makes sense, wood rottens.
01-16-2009 08:36 AM
sailingdog
Quote:
Originally Posted by Sailormann View Post
Well - you sound like you and your posse are ready to take on a big project so I'll wish you well. A couple of suggestions...

Don't pull the entire underside ot the deck off at one time. The boat will flex and you'll be epoxying a few bends and twists into the hull that shouldn't be there. Do it a small section at a time.
This is very good advice.

Quote:
Think about using an alternate method. Cut 2 1/2 inch longitudinal channels out of the existing underside. Lay in a 3/4" stringer (wood/foam/carbon fibre/whatever) and then cover the stringer with several layers of roving. Once you have a complete structure of stringers, finish it off with some trnasverese ribbing done the same way. Then core between the stringers - use Airex. Cover everything with a bit of roving.
This is more work, but probably a better choice in the long run.

Quote:
Remember NOT to use balsa in areas where hardware will pierce the deck. It is not strong enough from a compression standpoint. Use plywood. Make epoxy plugs on each hole.
Make the sections where the hardware comes through the deck solid glass that is tapered to meet the cored areas so you don't get a hard transition line if you can avoid it. Solid glass is a much better solution than pads of plywood, since the plywood can rot.
01-16-2009 08:27 AM
zz4gta I plan to document this repair the best I can to help others considering it's a pretty common problem. I got my bags packed for the weekend, going sailing saturday, and dropping the mast when we get her back in the slip. Also going to clean her out, and ready for the start on Feb 8th.

Sailormann, thanks for the tips!
01-16-2009 05:43 AM
SimonV I am just glad I have a dry deck, I would have messed (EDIT BY CD) it up. Good luck and keep us informed.
01-16-2009 12:12 AM
Sailormann Well - you sound like you and your posse are ready to take on a big project so I'll wish you well. A couple of suggestions...

Don't pull the entire underside ot the deck off at one time. The boat will flex and you'll be epoxying a few bends and twists into the hull that shouldn't be there. Do it a small section at a time.

Think about using an alternate method. Cut 2 1/2 inch longitudinal channels out of the existing underside. Lay in a 3/4" stringer (wood/foam/carbon fibre/whatever) and then cover the stringer with several layers of roving. Once you have a complete structure of stringers, finish it off with some trnasverese ribbing done the same way. Then core between the stringers - use Airex. Cover everything with a bit of roving.

Remember NOT to use balsa in areas where hardware will pierce the deck. It is not strong enough from a compression standpoint. Use plywood. Make epoxy plugs on each hole.

Good Luck - Post Pics !!
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