Help! I've got all the resin, hardener and fiberglass cloth for repairing and rebedding the starbaord stanchion this weekend. Except, I don't have the core material. My O'Day 23 has a balsa core. The section I'm replacing will be about 12" long and almost the width of the deck between the cabin top and toe rail (about 4.5") I only need that section done, but can't seem to get my hands on some core material, either balsa core or marine plywood. Help. The section isn't that big, but big enough that I'm doubting if I should just fill with epoxy resin only (due to it being the base for the starboard stanchion). Help...need ideas, recommendations. I've gone through the forum archive seeking ideas, nothing standing out. (unless I'm missing something). Mark
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Bob Vannier
Core Material
Mark: You could possibly use a product called KITTY HAIR. A long strand fiberglass reinforced filler, made by Evercoat. I repaired the center board on my 23 O'Day. It's a little tricky to use but after it cures, it's hard as a rock and can be sanded, drilled and pounded on. Fill the space. and sand. Then cover with fiberglass cloth and resin. With a normal backing plate it should hold your stanchion very well. Be sure to follow the directions on the can. A quart or about 3 lbs should do it. You may have to hold it in place with something while it cures. Good luck.
Mark: You could possibly use a product called KITTY HAIR. A long strand fiberglass reinforced filler, made by Evercoat. I repaired the center board on my 23 O'Day. It's a little tricky to use but after it cures, it's hard as a rock and can be sanded, drilled and pounded on. Fill the space. and sand. Then cover with fiberglass cloth and resin. With a normal backing plate it should hold your stanchion very well. Be sure to follow the directions on the can. A quart or about 3 lbs should do it. You may have to hold it in place with something while it cures. Good luck.
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kevin
core substitute
Have you thought about using an exterior grade plywood and coating both sides and all edges with epoxy resin? rumor on the street is that the only difference between marine grade and exterior grade ply is that there are no knots in the marine grade and there could be with the exterior. Home depot carries and exterior ply, I belive it's called ACT. this is an option. Also, check where you bought your epxoy resin and glass. they should sell a "foam" core material instead of balsa. The idea is that this foam would be soaked with epoxy to derive it's strength. You will use quite a bit of resin. Keep checking the archive and recent posts. THere are a few from a month or so ago about marine grade ply vs. exterior. good luck
Have you thought about using an exterior grade plywood and coating both sides and all edges with epoxy resin? rumor on the street is that the only difference between marine grade and exterior grade ply is that there are no knots in the marine grade and there could be with the exterior. Home depot carries and exterior ply, I belive it's called ACT. this is an option. Also, check where you bought your epxoy resin and glass. they should sell a "foam" core material instead of balsa. The idea is that this foam would be soaked with epoxy to derive it's strength. You will use quite a bit of resin. Keep checking the archive and recent posts. THere are a few from a month or so ago about marine grade ply vs. exterior. good luck
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Don Evans
Regular Plywood
For the area under the stanchion, I would use plywood only. Airex, and other foam cores are not recommended under areas of high stress such as stanchions, cleats etc. I would avoid the expensive marine grades, as you will be forced to buy an expensive 1/2 sheet at the least and you won't need it if the wood is coated with 3 coats of epoxy. You could fill the area with epoxy only, but thats a lot of expensive epoxy and you will have to apply it in stages...use plywood instead. Take your time, think it through and it will turn out just fine. Don
For the area under the stanchion, I would use plywood only. Airex, and other foam cores are not recommended under areas of high stress such as stanchions, cleats etc. I would avoid the expensive marine grades, as you will be forced to buy an expensive 1/2 sheet at the least and you won't need it if the wood is coated with 3 coats of epoxy. You could fill the area with epoxy only, but thats a lot of expensive epoxy and you will have to apply it in stages...use plywood instead. Take your time, think it through and it will turn out just fine. Don
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Chuck
Core Material
Had a problem finding balsa as well. I used these folks. No problems. I got the 9x11 pieces. Fast shipping as well. Chuck
Had a problem finding balsa as well. I used these folks. No problems. I got the 9x11 pieces. Fast shipping as well. Chuck
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Ray Nicolich
Just a Note on Plywood
New to the site and enjoying it very much.Just a note on plywood, from my experience, marine ply is considered, virtually 'void free', lacking missing knots between layers thus making it stronger and denser, and I believe a better grade of adhesive. Also, in plywood construction the # of ply's bears significance, the more layers the stronger the sheet.Most of the plywood(and most of the building products) now being sold from these nationalized corp. chains, like Home D., are a far cry from the products sold 20 yrs. ago and the quality of plywood is a perfect ex.
New to the site and enjoying it very much.Just a note on plywood, from my experience, marine ply is considered, virtually 'void free', lacking missing knots between layers thus making it stronger and denser, and I believe a better grade of adhesive. Also, in plywood construction the # of ply's bears significance, the more layers the stronger the sheet.Most of the plywood(and most of the building products) now being sold from these nationalized corp. chains, like Home D., are a far cry from the products sold 20 yrs. ago and the quality of plywood is a perfect ex.
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Brian
Core Material
I know how you feel, seems you can never find what your looking for when it comes to fabricating repairs. When you consider the size piece that you need and no balsa or marine grade plywood available, the next best alternative is red or white cedar. It works well and is often used as core material on custom fabricated boats. I would choose it over exterior grade plywood. The biggest issue for the repair is making sure there are no voids in the core repair(fill around replacment core with thickend epoxy)and make sure that the core wood is completely bonded to inner and outer layers of fiberglass. Take your time and plan it out. Good Luck!
I know how you feel, seems you can never find what your looking for when it comes to fabricating repairs. When you consider the size piece that you need and no balsa or marine grade plywood available, the next best alternative is red or white cedar. It works well and is often used as core material on custom fabricated boats. I would choose it over exterior grade plywood. The biggest issue for the repair is making sure there are no voids in the core repair(fill around replacment core with thickend epoxy)and make sure that the core wood is completely bonded to inner and outer layers of fiberglass. Take your time and plan it out. Good Luck!
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jim
Mumbers of Ply
all plywoods us alternating layers of wood as I assume you know, the differences is as said the care in laying up of the plywood. The glue for exterior plywood is "water proof" but only to a degree. The number of plys is far more impotant the interior/exterior in that the more plys the less stress there is in the plywood(look at 1/2 cdx at lumberyard and see how cupped/warped it is) The best plywood is designed for airplanes and is 9 or 11 ply for 1/2 plywood. Here in Ft Worth I ma able to buy 1/2 Baltic birch 5ftx5ft for $39 and it is 7 ply and very stable. I have seen some at Lowes/Homedepo in 2ft x4ft at 16 or so.It should be wonderful for you project. Good Luck Jim
all plywoods us alternating layers of wood as I assume you know, the differences is as said the care in laying up of the plywood. The glue for exterior plywood is "water proof" but only to a degree. The number of plys is far more impotant the interior/exterior in that the more plys the less stress there is in the plywood(look at 1/2 cdx at lumberyard and see how cupped/warped it is) The best plywood is designed for airplanes and is 9 or 11 ply for 1/2 plywood. Here in Ft Worth I ma able to buy 1/2 Baltic birch 5ftx5ft for $39 and it is 7 ply and very stable. I have seen some at Lowes/Homedepo in 2ft x4ft at 16 or so.It should be wonderful for you project. Good Luck Jim
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