This is an FYI for all you C27 owners out there. On my 1 980 C27 I'm finally getting around to repairing the wet areas under the mast and cabin top(ceiling) under the sea hood. I've done deck repair before but what makes this more difficult is the approximately 2 1/2 inches of plywood Catalina decided needed to go in the channel that runs port and starboard of the mast. A circular saw and sawzall does a lot of the work but getting down to the glass meant having to grind/chisel the polyester resin filler that the plywood was set in. The glass of the channel itself is fairly thick but the glass under areas aft of the channel are very thin. The way Catalina built these boats was to make the headliner of the cabin the bottom skin of the sandwich construction . They did not lay up a bottom skin separate from the headliner. That is, there is no bottom skin to the plywood core. When they mated up the headliner with the mold of the cabin they set the liner in this polyester bedding material (slurry/mush) which is very thick in some areas. Hope this description of the construction is clear.
Inside the cabin of my boat the port side of the cabin ceiling in the salon area is oozing a coffee colored liquid which I assumed was because of wet plywood core. But because of the thick slurry of bedding material I can't be sure the coffee colored stains weren't coming from the bedding material. So, I'm chipping away at the bedding material. After chipping away a square foot section this is when I saw how thin the headliner skin is. It flexes very easily when pressed. I will layup a couple layers of 1708 over the thin skin to add stiffness to it. Maybe I didn't need to chip out the bedding material but it is polyester and maybe holding moisture that causes the coffee colored stain. Attached are pics of outside of the cabin.
Inside the cabin of my boat the port side of the cabin ceiling in the salon area is oozing a coffee colored liquid which I assumed was because of wet plywood core. But because of the thick slurry of bedding material I can't be sure the coffee colored stains weren't coming from the bedding material. So, I'm chipping away at the bedding material. After chipping away a square foot section this is when I saw how thin the headliner skin is. It flexes very easily when pressed. I will layup a couple layers of 1708 over the thin skin to add stiffness to it. Maybe I didn't need to chip out the bedding material but it is polyester and maybe holding moisture that causes the coffee colored stain. Attached are pics of outside of the cabin.
