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Hi, im looking at redoing my decks next spring on my 41 morgan out/island.. i know big job! I would like to get feedbacks from people who have dealth with this kind of job. Most of the core is rotten or moist..im thinking about using close cell foam as a core instead of a wood core and add glass on ribs in between the laminates to add strenght. Any suggestions will be much appreciated. thanks
 

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Have much experience with core repairs large and small.I prefer Coosa foam panels and epoxy resin.Use their stiffest grade panel (it has glass reinforcement built in) and you wont need any other structural support ,at least in open deck areas.Read West System Fiberglass boat repair.
 

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Definitely epoxy instead of polyester. Balsa is still one of the best if not the best core material. Conforms to dercks that are not flat, reasonably inexpensive, bonds well abd by design water will not migrate easily. Whatever core you use, make sure no bolts go through core - solid at those locations. If that had been done originally there wouldn't be such an industry recoring decks.
Brian
 

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I recently redid my decks. Yep it was hard. My PO had started the repairs from below, which made it even more difficult. I like Balsa. I used Marine Grade plywood under the genny track areas and Balsa everywhere else. I overdid it with thickened epoxy and left extra room for solid core around any hole in the deck. And then I glassed upside down! Don't overthink it. Jump in. Do it. When you finish you can say, "I'm Done!" I had a helluva party afterward, let me tell you.
 

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One of the best things I did was set up scaffold around the perimeter, so that instead of trying to bend over on my hands and knees the whole time, I was a a very comfortable height. Purchase your own moisture meter, and learn to use it. You can easily recoup its cost by not opening areas which are sound. I used a sharpie to do readings on the entire deck, then starting at the highest readings, drilled cores, working down the #'s till I hit dry core. Several more cores from lower readings confirmed I had all the moisture. Working alone I could cut out with a skil saw, bevel deck edges with an angle grinder with a 36 grit flap wheel, chisel out wet balsa with a 1" sharp chisel and a comfottable hammer, clean up and vacuum repair area, grind smooth bottom skin, fit and bond new balsa, and bag on 2 layers of glass in 6 hours to about 20 sq ft. measure and layout everything dry before you start. Work in bite size pieces you can handle each day. If you have genoa tracks, and other assorted hardware to areas you remove, before you apply the top skin, use the old fiberglass that you removed to mark where the bolts went through, and over drill and fill with thickened epoxy. easier to do it before you glass, than after. Have fun.
 

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Balsa is a good core material. It's strong and light. Because it is end grain if any water does get in it will not travel far. Plywood is the worst core. It's heavy and if water gets in it will travel between the plies and cause big problems. Also balsa will follow the curve of the deck better.
 

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I'd highly recommend you read this post on cored GRP construction that I wrote. It talks about the pros and cons of the different core materials, as well as the pros and cons of some of the materials used in GRP construction-like Carbon Fiber, Kevlar, and fiberglass.

I'd also point out that re-coring a deck from the top is generally going to be far easier and faster than trying to do so from underneath, since gravity is working for you and you're far less likely to layup the repair with voids.

Also, try and make solid fiberglass pads for the areas you will be mounting deck hardware. If you can't do that, at least make sure you properly rout the core material out and pot the holes with thickened epoxy to protect the new core from water intrusion.

I think i will be going with wood instead of foam ...I prefer the strengh, feel ill be more confortable working with wood... im not sure if ill use balsa or plywood. Any suggestion?
 

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catamount

i was looking forward to learning from you pictures but there seem to have broken links today
My hosting provider seems to be having some problems this morning. Perhaps bandwidth issues related to Vancouver Olympics because I think the server my site is running on may be in that area? All I can suggest is to check back later.
 

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Definitely check out Tim Lackey's restoration of Glissando, pointed to by mitiempo. Also, West has a well written article on repairing the Balsa Core here.

For material, if you would like to try the material that the US Navy uses (not affected by moisture, has better structural properties than balsa, but weighs a little more), send me a PM, and I'll put you in touch with the manufacturer.
 
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