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Re: Injecting epoxy in wet core
Clearly replacing the core is the best option, but often is not logical in an older boat used for coastal cruising, where the cost of the repair could easily exceed the value of the boat. It's a lot of work, make no mistake. I have done the job and my repair is in an issue of Good Old Boat in 2004. I wouldn't do it again. First, why return an ancient deck to as new condition? Have you seen decks fail? In my 45 years of being around boats, I've never seen one failed deck. So ask yourself "what am I trying to achieve here"?
If the core is not rotten epoxy injection is good. Very expensive yards use this as the method of choice, including Morris Yachts. It makes zero sense to rip out sound core to replace with more sound core. (Although many will happily charge you thousands of dollars to do just this). Acetone can be injected periodically until it's dry. Or you can use Boatlife Aquapoxy which cures well in wet wood. Size of the repair does not matter. Then inject unthickened epoxy. Do not thin it. If the deck core is rotten, you might consider injectadeck, which is a 2 part structural marine foam that remains liquid for the first 30 seconds or so, and penetrates into any cracks, crevices or gaps. It is attracted to moisture, and cures better in the presence of moisture. It then expands, and cures rock hard. Of course, you might get some small voids, but the deck I have seen repaired with this method is absolutely rock hard. Another approach might be the one taken by Aeromarine Industries, (see their video on deck repair). They inject structural foam between the overhead liner and deck, then epoxy into the dry deck core. This looks massively strong. If the core was wet and rotten, I'd use injectadeck into the core or Aquapoxy, but definitely not regular epoxy. None of these methods are perfect, but they do work, and can keep your boat going safely for many, many years. They are also about 1% of the work of replacing the core. Replacing the core would be an absolute last resort for me, and only if I planned to use the boat in extreme offshore conditions.
Last edited by JamesRichy; 02-25-2018 at 04:31 PM.