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Old 03-18-2019, 11:03 PM   #1
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Our boat deck has been removed.

Made the turn from removing to prepping for new decking today. Feels good. Hope to be installing new plywood this coming weekend.

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Old 03-18-2019, 11:32 PM   #2
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Well, good luck with the rebuild. Ambitious project. Keep us up to date please.
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Old 03-19-2019, 12:56 AM   #3
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Always feels better when the cancer is cut out.
Doing our decks a 4ft x2ft section at a time while living aboard and without the luxury of a shed.
Getting there, slowly but surely.
Have fun.
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Old 03-19-2019, 11:10 AM   #4
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Always feels better when the cancer is cut out.
Doing our decks a 4ft x2ft section at a time while living aboard and without the luxury of a shed.
Getting there, slowly but surely.
Have fun.
It sure does. We would've preferred to remove/replace in sections but after pulling up the teak and glass and seeing the previous "repairs" we made the decision to just replace it all at once. Should make glassing, fairing and finishing easier with a better end result.

The covered moorage and living on land certainly make this easier. I'm picking away at it on nights and weekends but think an experienced crew could easily replace the deck in a week. I'm much slower because I'm considering every step.
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Old 03-19-2019, 12:00 PM   #5
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You are one courageous and adventurous individual.
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Old 03-20-2019, 11:15 AM   #6
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Undertaking projects like this make me hesitate. It literally is a can of worms that has no solution other than to bow your head and charge. Of course, having covered storage helps, but it’s still no less than tearing apart your boat. Please keep us informed. If we want to save our ageing vessels, lots of us will eventually face the challenge. Best of luck.
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Old 03-20-2019, 12:35 PM   #7
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Nice job. Now you have a clean canvas to work with and the framing looks to be in really good shape. I just did a water tank project on mine that I wish I would've dove in and did it the way it really needed to be done, but I just didn't have it in me. Your're making great progress. Thanks for posting.
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Old 03-20-2019, 12:37 PM   #8
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What made you decide to remove/replace the lower glass skin?
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Old 03-20-2019, 01:05 PM   #9
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Good for you. Please provide plenty of pics.

Is that a heavily trafficked deck? Just trying to visualize what might be under mine for the supporting skeleton.

What are you using for materials? Plywood type and thickness? Fasteners? Glass type? Resin type? Fairing material? Paint or gelcoat or other finish?

An inspiring project! Thanks.
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Old 03-20-2019, 04:31 PM   #10
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Wow, Steve- talk about jumping in with both feet!
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Old 03-21-2019, 11:40 AM   #11
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Undertaking projects like this make me hesitate. It literally is a can of worms that has no solution other than to bow your head and charge. Of course, having covered storage helps, but it’s still no less than tearing apart your boat. Please keep us informed. If we want to save our ageing vessels, lots of us will eventually face the challenge. Best of luck.
You're right about that! I found a little delamination in the back of the pilot house where it's joined to the boat deck so I found myself considering playing the "now or later?" game. I will likely be later as I'd like to re-bed the windows at the same time. Gotta keep the projects as phases with lots of boating in-between!
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Old 03-21-2019, 11:42 AM   #12
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Nice job. Now you have a clean canvas to work with and the framing looks to be in really good shape. I just did a water tank project on mine that I wish I would've dove in and did it the way it really needed to be done, but I just didn't have it in me. Your're making great progress. Thanks for posting.
Yes, very fortunate the framing is in decent shape. Sawn mahogany has it's advantages. I do need to deal with two small sections where someone forgot to beed the stanchions. I'll likely repair with epoxy as I'm not concerned about pullout.
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Old 03-21-2019, 11:47 AM   #13
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What made you decide to remove/replace the lower glass skin?
The way these Bluewater Yachts were built was 23/32 marine ply on sawn mahogany frames with a layer of chopped strand on top. We also had the optional teak deck on top of the glass.

So, no lower glass in the sandwich.
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Old 03-21-2019, 11:54 AM   #14
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Good for you. Please provide plenty of pics.

Is that a heavily trafficked deck? Just trying to visualize what might be under mine for the supporting skeleton.

What are you using for materials? Plywood type and thickness? Fasteners? Glass type? Resin type? Fairing material? Paint or gelcoat or other finish?

An inspiring project! Thanks.
Thanks?!

Yes, this is the boat deck and really the main outdoor space for us. We're up there, the dinghy is up there, the dining table is up there, etc.

Replacing with 3/4" marine ply (six sheets). We'll route finger joints between the sheets, join with epoxy and epoxy the ends. Fasters will be SS screws, likely square drive but I'll need to consult with the folks at Fisheries. One of the more impressive things about deconstruction was removing hundreds of perfectly preserved SS screws.

I may need to cut longitudinal kerfs on the underside to facility the curve. We'll run some tests and see if we can get the bend we need. I don't want to put unnecessary pressure on unsupported frame spans.

After that it'll be sanded and filled then wetted out well (avoiding the original issues) likely using chopped strand followed by mat. Again, I need to consult on that one.

Open to suggestions.
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Old 03-21-2019, 11:55 AM   #15
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Wow, Steve- talk about jumping in with both feet!
Thanks Pete. Don't tell anyone I know how to do this stuff
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Old 03-21-2019, 12:44 PM   #16
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Dang, Fort. Now that I see this is open at the bottom, is the plan to fit the plywood and then finish it before laying it down? How committed are you to the chopped mat? I admire ya, Boy.
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Old 03-21-2019, 03:27 PM   #17
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No commitment made to the glass yet. Yes, we'll fit the plywood, glue and screw to the fames, then fill, wet out and glass.
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Old 03-21-2019, 04:50 PM   #18
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I have had good luck with 1708 and epoxy but for much smaller projects. Easy to work with and strong. Might need fairing before final paint or gelcoat.

As to CSM - it seems it apparently doesn't work as well with epoxy as it does with polyester or vinylester resins:
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Old 03-23-2019, 11:06 AM   #19
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No commitment made to the glass yet. Yes, we'll fit the plywood, glue and screw to the fames, then fill, wet out and glass.
What about the frames themselves ? Are they in good condition or would they benefit from also being (re) epoxy sealed?
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Old 03-23-2019, 12:21 PM   #20
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Greetings,
Mr. CP. I knew that there was a specific glass for epoxy but never knew the reason. Meaning one can use any glass for poly but only one type for epoxy. Thanks very much.
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