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Old 04-16-2014, 12:20 PM   #23
Brooksie
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City: Cape Cod, MA
Vessel Name: Island Seeker
Vessel Model: Willard 36 Sedan
Join Date: Oct 2007
Posts: 1,306
I have had good luck over the years repairing balsa cored foredecks and cabin overheads on my Bruno-Stillman (not the Willard) and friends' boats by using this, non distructive method if the area can be reached from inside.
Sound and mark out the area, drill 3/16 holes every 3" throughout the entire area through the inner skin AND balsa. Tent it with a dehumidifier till no more water shows in the collection bucket. Inject the holes, one at a time, with glass micro-balloon thickened epoxy moving from one hole to another and plugging the holes with sheet metal screws. Injection by syringe, empty caulking cartrige, or grease gun depending on situation. Cure, remove screws, patch holes.

This makes a very solid permenent repair without a lot of distructive glasswork and grinding.

PS: Extreme care must be used when using a grease gun because of the pressure available.
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