Deck Delamination in a Catalina 30

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Bill Wilson

We have a 1977 Catalina 30, which we have enjoyed with few problems for the last 10 years in a three family partnership. This year our insurance company required a new survey of the boat. The surveyor reported that there were very high moisture readings in the cabin top, around and in front of the mast step, along the sides where the windows are and some high readings in portions of the side decks. He also said that soundings indicated some significant core delamination in several areas. However, there are no external signs of deck flexing or cracks in the gel coat. Even under heavy load, everything seems very solid. To repair this problem we apparently require extensive portions of the deck removed, the rotted core material replaced, and the deck surface reinstalled and refinished. We had an estimate for these repairs which was about $25,000 CDN. This is equal to the value of the boat and it does not make any sense to put that much money into it. We would like to hear about other peoples experience with this problem on an old Catalina boat. We would also like advice on alternatives to the repair that we can do ourselves and which would be much less expensive, or any alternative course of action someone could suggest. We have been happy Catalina owners and would like to continue to enjoy our boat without having to spend a fortune to repair it. Thank you for any help you can give us. Bill
 
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LaDonna Bubak - CatalinaOwners.com

Ouch!

The only proper fix is to scrape out the rotten coring and repair. A temporary fix would be to drill holes to let the coring dry out and then squirt penetrating epoxy in there. Unfortunately, this is not a long term solution. Keep in mind that just cuz everything "looks" strong, doesn't mean it is! I'm sorry for your troubles but this serves as an excellent warning to boat owners to rebed your hardware to not only prevent leaks but to prevent rotten coring. I wish you the best of luck! LaDonna
 
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James

Get Another Opinion

This seems excessive. I have not seen any significant deck delamination in Cat 30s. Yes, around the mast step can be a problem, but the factory has a repair for the problem that is pretty straigh forward. Such widespread moisture penetration as you are describing is unusual. In fact, I've never heard of such. The factory laid the glass on the decks pretty solid around marine grade ply core. A second opinion from a reputable surveyor is warranted. James s/v Neveland Dana Point, California
 
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SEan

2nd the 2nd opinion

soundings and moisture readers will not give you the truth behind the problem. I would drill some small holes and see how wet the coring actually is and how large of a problem it has become. I usually agree with Ladonna, but if you have no external signs and you sail your boat regularly, than I would think that any delamination of this magnitude would definately show through. I would go the pentetrating epoxy route first unless the core you pull out is drippin wet.
 
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Tom

How to do it...

Bill - Don Casey's book 'Sailboat Hull & Deck Repair' has some very clear and helpful directions on repairs of this type. You may want to check it out. All the best, Tom
 
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