C&C 24 bow hatch deck repair

[darmyvt]

I've searched the web far and wide, including C&C forum on this site, and can't find anything regarding deck under/around bow hatch of a C&C 24... 1983 C&C 24 leaking hatch: Plexi/lexan is fine, rubber seals are iffy but hatch bedding is toast. Removed the whole assembly to find the attached pics. Many screws weren't holding at all... It appears that the ~24"x24" area around the hatch was sandwiched with foam or epoxy putty?? Additionally, I think someone must have added a little putty, which I removed prior to these pics.
My question to the group is how would one fill this void, to also provide structure for hatch screws? My thought was epoxy putty, but there isn't enough room to trowel it in there in it's current condition. Cut the top deck back and then properly replace it? How far? (But this is more work than I'm ready to do at the moment.) Cut the upward facing face of the lower pan, trowel putty in, and leave that face off? I'm not totally useless when it comes to repairs, but I don't want to open the whole deck this spring.
Thanks for looking and ruminating with me.

 

[dlochner]

Thickened epoxy will work. There are a couple products well suit for this, West System Six10 and TotalBoat Thixio.

Use a heavy duty caulking gun to force the epoxy into the void after cleaning out all the loose stuff in there. It may be necessary to drill the mounting holes to a larger size and then inject the epoxy to provide a solid base to mount the screws.

Don't bother with the cheap caulking guns, the epoxy is pretty thick, the cheap guns are not up to the task. Also get the epoxy to room temperature. If it is cold it more difficult to squeeze out of the tube.

 

[darmyvt]

Thanks Dave, great input! I considered injecting, but wasn't sure about flowability of some of the stuff I've found. I'll check out your links.

 

[shemandr]

I was thinking about using fiberglass mat as per Andy at Boatworks Today. I think he would use the mat with polyester resin stuffing the wetted mat into the voids.
I have to admit that the Thixo would be easier.

 

[fred1diver]

I second the six10 it is amazing product or you can mix epoxy and add fillers to it, they sell tubes you can fill with your own and use it with a caulking gun as well

 

[darmyvt]

Thanks guys. Access (without cutting open deck) is tight to nearly zero. West Marine (big price markup, but local) has six10, so I'll prob give that a shot. So grateful for the input!

 

[fred1diver]

With a tube of six10 you can do many repairs, make sure you get extra mixing tips to use later