Port replacement

[geek_guy]

We purchased a 1987 Hunter 37 last spring. It has plenty to do..

I took out one of the port lights yesterday to replace. Got it out and was ready to pop the new one in when I saw that the plywood between the fiberglass is literally gone at the bottom and one side. The other side is wet as evidenced by pushing my thumb nail in and seeing moisture bead.

My question is how to proceed. Seem easier to me to just mix up and pour epoxy in the void till it fills up. Then sand and install port again. But I had seen other information about putting new plywood core back in. I suspect the rot goes quite a ways down into the deck.

Opinions please!!!

 

[quadrille38]

I think you may be partly right on filling back with epoxy but I think you need to get the rotted wood out as far as you can before doing so. Otherwise I think it will continue to spread. There used to be a a product called Git Rot that was used to kill off the stuff eating the wood. Not sure it's still out there but consider it.

Had something similar on a previous boat. Used a combination of tools to get the wet rotted wood out. Have even read of people using a dental pic type tool.
Shop vac and digging until you have it out.

Then a hair dryer or careful use of a heat gun to dry further.

The epoxy solution after that. I'm fond of West Systems epoxy.

 

[Steve Dion]

Ditto on the GitRot. Then you can fill the area and seal it with epoxy so that do not happen again.

http://www.jamestowndistributors.com/userportal/show_product.do?pid=2093

 

[Stu Jackson]

Here's Maine Sail's How To Do It

http://www.pbase.com/mainecruising/sealing_the_deck

 

[Mark Price]

I replaced all my port a few years ago with NFM SS ports. It was a BIG job but was fun and for the most part I wroked alone. Used a router to remove the wet wood West Systems epoxy to fill and router to get correct pattern for new ports. Here is a picture of oe of the port openings with the wood removed.

 

[Mark Price]

You can find more photos in my album or just PM me if you want to talk about going that route.

Mark