For any one interested:
I started recoring the decks today. Cut out the cockpit floor. I
wanted to cut all of the section to be done at one time (the less
days covered in fiberglass the better), but decided to at least start
in sections. I used a circular saw set at 3/8" and then a cut off
wheel in a grinder to finish the corners. Top skin popped off fairly
easily. Most of the balsa core was mush though some was still like
new. A putty knife and a wooden mallet cleaned up the blasa core
nicely, and I used a fat screw driver to clean out the edges. Then a
fat grinding wheel over entire inside and underside of top skin.
Other than all the fun fiberglass dust, went pretty quickly and
easily. Interestingly the square of plywood around the gas fill (She
now has a yanmar diesel with a separate fill but the old gas fill
fitting is still in the cockpit floor) was wet but solid. Says alot
for the quality of plywood back in the 60's. Tomrrow I plan to cut
Marine ply pieces to fit in place of the balsa core. If weather
holds, on Monday I'll epoxy in two layers of glass mat then marine
ply and two more layers of mat and then the top skin. Then it's off
on vacation for a week (what!?! I thought boat work was vacation!!).
I know some folks say to use foam core and some say marine ply. I'm a
wood man, and foam core while it doesn't rot still turns to mush when
water gets in. I've seen plenty of rotton foam core decks and hulls
to have the opinion that good marine ply will last longer if water
does get in. Foam or ply, the key is to encapsulate it in epoxy and
don't let the water in.
I'll keep you all updated as project moves along.
Bob
SV Gabba Hey
1964 #90
