Deck lifted exposing rotted core

Deck lifted exposing rotted core

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DSCN8409 Where it all started, now finished.

DSCN8409 Where it all started, now finished.

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DSCN8404 Interior nearing completion.

DSCN8404 Interior nearing completion.

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Interior5 Interior pieces prior to paint. Notice long strips along the V-berth section. Instead of placing the new section over the 2" section left behind, I scabbed these pieces underneath cut the new section to fall into place.

Interior5 Interior pieces prior to paint. Notice long strips along the V-berth section. Instead of placing the new section over the 2" section left behind, I scabbed these pieces underneath cut the new section to fall into place.

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Cabin1209 V-berth "patterns". I cut the oval holes in these areas to acces space that would otherwise be inaccessible. I did this a few years ago in place, and in the replacement wood before installation.

Cabin1209 V-berth "patterns". I cut the oval holes in these areas to acces space that would otherwise be inaccessible. I did this a few years ago in place, and in the replacement wood before installation.

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Cabin3 Companionway view of stripped cabin.

Cabin3 Companionway view of stripped cabin.

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Cabin1202 V-berth area. Notice the hole drilled on the forward vertical surface of the sole pan. This was glassed over, as was the aft hole. Water was retained, and at best would seep to where I could removed it, but caused the rot in the bulkheads adjacent.

Cabin1202 V-berth area. Notice the hole drilled on the forward vertical surface of the sole pan. This was glassed over, as was the aft hole. Water was retained, and at best would seep to where I could removed it, but caused the rot in the bulkheads adjacent.

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Cabin1050 Bunks removed. Bunk supports were also removed and replaced. The bunks are glassed to the hull, so I cut them with a jig saw about 2" in, cut the new bunks from the pattern and added the 2", then installed them over the old edge and screwed them in.

Cabin1050 Bunks removed. Bunk supports were also removed and replaced. The bunks are glassed to the hull, so I cut them with a jig saw about 2" in, cut the new bunks from the pattern and added the 2", then installed them over the old edge and screwed them in.

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DSCN3843 Adhesive is 3M 5200.

DSCN3843 Adhesive is 3M 5200.

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DSCN3839 Deck bedded to hull and pressed into place.

DSCN3839 Deck bedded to hull and pressed into place.

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DSCN3530 Old bulkhead was used as template for shaping 12mm PVC foam.

DSCN3530 Old bulkhead was used as template for shaping 12mm PVC foam.

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DSCN2957 Aft bulkhead removed.

DSCN2957 Aft bulkhead removed.

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Aft bulkhead cut and kicked out of place. Cockpit support tube has been removed to accomodate a 20 gallon water tank that now acts as the support.

Aft bulkhead cut and kicked out of place. Cockpit support tube has been removed to accomodate a 20 gallon water tank that now acts as the support.

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DSCN3790 While up I filled all the holes drilled along the gunwale after grinding out the area around them to a uniform depth. Filled with a little filler putty, but mostly glass cloth and resin. Putty offers little structural strength.

DSCN3790 While up I filled all the holes drilled along the gunwale after grinding out the area around them to a uniform depth. Filled with a little filler putty, but mostly glass cloth and resin. Putty offers little structural strength.

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DSCN3527 This is the replacement PVC foam material with resin poured over it (I just had extra resin so figured it wouldn't hurt).

DSCN3527 This is the replacement PVC foam material with resin poured over it (I just had extra resin so figured it wouldn't hurt).

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DSCN3415 These are the 4" pieces of ply used for core filler when manufactured.

DSCN3415 These are the 4" pieces of ply used for core filler when manufactured.

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DSCN3525 Deck lifted. The bow proved the most challenging. The pin in the anchor locker goes through the hull and deck, and is glassed over.

DSCN3525 Deck lifted. The bow proved the most challenging. The pin in the anchor locker goes through the hull and deck, and is glassed over.

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DSCN3370 This is the port rear stanchion area I was having water intrusion.

DSCN3370 This is the port rear stanchion area I was having water intrusion.

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Mark Major

Gunwale core replacement and subsequent wood replacement

Chasing a leak took me places I'd never imagine. This started as a repair at the base of a stanchion. I removed the deck, replaced the gun'le core, then most of the interior. The aft bulkhead was replaced with 12mm PVC foam, and the scrap from the sheet I used to replace all the functional exterior teak.
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