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I plan to start this task next month on my boat. I'll be using balsa core and wanted to get some opinions on bedding hardware and using a liner as outlined in another post here on sailnet. I just want to make sure that a skim layer of FG is not required on the inside for strength. I plan to do the re-core from the inside leaving the outter decks untouched. (I know, I know).

I'll keep updating this post with pictures and progress. Hopefully I can have the repair done with 100sq ft of balsa, and minimal down time.

Here are the steps I have outlined
1. drop the mast and remove hardware
2. strip insides of anything important, vests, gear, etc.
3. start from the companionway and cut sections of deck out working my up to the bow.
4. plug all hardware holes to keep out rainwater, and allow a week to dry.
5. begin cutting and expoxying new balsa in place, same order as it was removed.
6. epoxy over all exposed balsa to seal it. Let it cure.
7. drill new holes and install hardware.
8. cut and install liner.
9. put the stick up.

WAAAY easier said than done. I'm not looking forward to this.
I thought you were planning to circumnavigate Delmarva this coming spring!? :D :D :D

More seriously, would it be at all possible to unbolt the deck and flip it over to do this work? It sounds daunting, but I think it would save you a ton of time in the long run and also yield much better results.
 

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...from what I've read, you need to haul the boat for "deck removal", and also make a jig so the FG deck shell doesn't twist in odd directions while you're repairing it. It's also considered to be extremely hard to refit the deck to the hull. Most of the time one or the other has tweaked while they were apart, and now doesn't fit properly.
Okay, for some reason I thought you had your boat on a trailer/cradle in your driveway. Regardless, you make some valid points about keeping the hull and deck in the proper shape. I think it could be done (with the boat hauled, of course), but no doubt it would be a major undertaking.

Then again, what you are about to embark on is no picnic.:eek: I would really think hard on the advice from Mainesail and others who've tried or seen this tried.

P.S. Also, you might touch base with ArtbyJody. He was facing some serious work on his Catalina 27 but eventually came to a different solution.
 
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