new core

here are two shots of the new core on the port side of bye all. the core material is douglas fir end grain. I used a chop saw and cut them to .650. I used west system 105/205 with the 406 add. its solid now. doing the same on the starboard aft quater and any other spot that contains over 15% moisture reading.

core removed

here are two photos of the decks with an area of the core removed. the next step is to prep it for epoxy and cut new core to fit. my biggest problem right now is the tempature.. epoxy needs 40 degrees to cure and at night it will be too cold and wont kick. looks like ive got to wait a few days... this weekend this section will be done.

deck repair

So I spend the winter removing the teak decks off BYE ALL, now that they are gone I ran a moisture meter over the core to see what I really had. I found alot of wet wood so I took the ol skillsaw and opened up the top layer or 1/8 inch glass. I found teak hardwood blocks about 4 inches sq. A few peices of plywood too. First I thought I could dry it out, so I put some fans on the decks and about 1 wk later not much improvement. If it was a balsa core it would probably have been rotten, but the end grain balsa would dry much faster then side grain teak. I purchased a 105C kit from midwest supply (5gal of west system) and last night I started with removing some core on the port side by the aft trunk. Ive spoke with Tom H. quiet a bit at Gougeon Brothers. He had many helpful ideas for this project. Im going to buy some half inch ply from home depot and cut it into 4 inch blocks and us the 105/205 with some 406 for bonding the new core to the existing layer of glass. after that I will rebond the top layer of 1/8 inch glass to the new core and do a 12:1 to make a strong structrual bond on the top later of the glass. I will follow up with a single layer of 15oz biaxial cloth and then paint nonskid.

here are a few photos of what ive been doing