Originally Posted by capeshore
Thanks, you were clear.
I have to do that deck. Was considering putting a hatch in where the rudder post is? Curious how that deck work went for you, any tips etc. Thanks!
Straight forward repair but I did it in the middle of florida summer so it was hot and kept raining on my handywork(even when not predicted). I planned on doing a spot repair so I cut out a 2'x2' square and that turned into the whole back deck.
Make sure no rain for a few days.
You can do the back deck in one swoop but keep in mind you wont be able to walk or support any of your weight on it after you remove the coring.. Plan accordingly(the bottom layer of glass is thin.. IMO too thin. Hack away at the top layer because it's too thin to reuse too.. YMMV Be very careful with the bottom layer because you'll be reusing that. Add another couple layers of fiberglass to it before you do the coring.. Much stronger.
It was difficult for me to get the shape just right(the curve) so I was forced to create the curve with sawdust/resin putty mix which worked okay. I tried to work with one large piece of coring material which I found out is totally unnecessary. Small chunks are easier to work with, will shape better and is strong.
Bring and air compressor and an air chisel to remove the rotted out core. I didn't but the job would have been quicker/easier.
Consider seacast pourable coring material made for decks. It's expensive but honestly you'll have alot of leftover, runs to the lumberyard, splinters, and work. Better yet it can't rot.
No matter how much resin you think you'll need double it(same goes for everything else). I'd buy 5 gallons because you will use it elsewhere. I didn't use that much though.
It's going to be more expensive than you think. Consider that the rear deck of the boat is larger than some center console's whole deck.
Buy a small 4" circular saw.. I got a black and decker one from walmart for under $90 and use it alot. You can set the depth so you don't cut through the bottom layer and work in tight spots vs a large circle saw.
Read about making your own peanut butter/thickened resin.. Also don't apply that stuff thinking you'll just sand it smooth later.. it's rock hard. Silica mix works well.
I'm very happy with the results.. I will say i've gotten some very very good results on smaller harder to reach places by drilling and injecting Gorilla Glue(works better than injecting resin). Waste of time and money in large areas though.
A hatch would work great but remember that you're weakening the deck by not carrying it all the way across so layup more fiberglass than others.