Here is a photo story on how I repaired my organizer cover. This post and a second post are involved:
Looking at the bottom of the cover, after I cut away the fiberglass covering, you can see the square blocks of wet plywood.
Here is the cover with all wood blocks removed. I used a Dremel to cut around the edges and a vibrating tool to cut under and loosen the blocks.
The cover is curved, so in order to hold that shape I used two blocks of wood under each of the aft corners. When the center is flush to the surface the curve is correct. In a later picture you will see that I used paint cans as weights to hold the epoxied foam tight to the inside surface of the cover. Without these corner blocks the cover would have been distorted from its original curve due to the weights.
There was another layer of fiberglass cloth on the very inside of the cover that I removed. I then used acetone and lots of rags to remove any mold wax that could have been left from the manufacturing process. The fiberglass was not adhered well and that is why I thought there could still be mold wax.
I bought this foam from Jamestown Distributors along with all of the West System supplies. They offered a repair kit with a gallon of epoxy, tools, and cloth. I found that to be the best deal. I bought two sheets of the foam to make the filler. I used two 1/4" thicknesses instead of one 1/2" piece because I thought it would be easier to bend to the curved shape of the cover.
I had to piece the foam together since the sheets were not large enough to cover in one.
The top piece (#1) had a curve that I allowed by cuts most of the way through.
The second layer of foam had more pieces to fit. No problem.
Here is the West Systems kit that I bought.
More images and details in the next post. I am at the 10 picture limit!