deck core repairs

[Mark]

I've begun the process of doing some fiberglass and core repairs on my O'Day 23. I'm new at it, so please understand that in this posted message. My most significant repair is to the starboard stanchion. The base to the stanchion was torn through on 3 of the 4 sides at the base of the stanchion, causing the stanchion to lean, giving rainwater clear access to the interior of the boat. I knew the core would be damaged and needing replacing, which I've started removing the stanchion and gutting out the bad core. At that same time, my son mapping the boat for delamination and other possible core problems. It apepars clean sounding all the way around, the boat, except on the starboard side, just aft of the forward starboard side. So, a second spot with possible problems. The one I already knew needing rebedding was the starboard rear stanchion, will I have to do the other? My question is, why would there be possible core problems on only ONE side of the boat? I've got Don Casey's book on Hull & Deck Repair, yeppers, I'm a DIY (God, please help!) Is there an easy way of doing this rebedding, 'n fixing core problems or is it really that easy?????Mark

 

[Brian Harrison]

DIY Repairs

You didn't specify if there is any laminate damage. I'll assume there isn't, and say that's the same stanchion that I had fold all the way through the deck. What a pain. The easiest repair if the surounding deck is solid is to use a bent nail in a drill to hollow out the damaged core. It will take several bent at different lengths with the heads cut off and that end chucked in the drill. Next I fill the damaged area with West System epoxy and 404 filler. West system has a manual on this type of repair that is concise and complete. If the damage covers a larger area, then the repair is more in depth. If not this repair will work fine. I also use an oversized backing plate of 5052 marine grade aluminum or 316 stainless steel. Good luck.

 

[Mark]

core

Brian,Yes, there's laminate damage. the only side that was really holding that stanchion upright and in place was the outboard side, all three other sides had completely torn. I still have the laminates on both sides, but they're pretty uneven and damaged. Core is is rotted out and bad. There is a backer plate, which is still in good condition though.I appreciate your advice though. Mark

 

[Brian Harrison]

Time to relaminate

It sounds like it is time to remove the damaged section and relaminate. At this point I have to say this might be cheaper to have done than do it yourself. If you decide to do it you will need some specialty items. Epoxy resins and laminate material are easy to find, but getting the right gelcoat mold can be more difficult. It is a tricky repair especially matching the gelcoat, but can be done with care and planning. A word to the wise is to check the other stanchions and rebed them as well when you are doing this repair. It will pay in the long run. If you have any questions feel free to ask. Good luck