Replacing OD22 Cabin Sole

[JoshGray]

In the next two weeks I will be replacing the cabin sole on my OD22 'Cassidy'. These forums have been a great resource while I researched this project. I intend to cut the top 'skin' of fiberglass off, scrape out the rotten balsa, replace core, expoxy top skin back on and then fair it all in with colored expoxy/gelcoat. My question is this: what would you use as a core material? The original balsa is 1/4" (I actually measured 5/16", but most people here seem to think that it is 1/4"... epoxy will make up any difference). I had originally thought of using marine plywood, but I am starting to think that this might be overkill (and too much $) because everything will be sealed in tight with epoxy. Could I get away with using some other (cheaper) material such as normal 1/4" hardwood ply? Mat would be nice, but this is also prohibitively expensive. Aside, this will be my first experience with epoxy and fiberglass. I am also planning on reinforcing the junction of the cabin top/sole and the compression post with SS plates. The bottom is no problem (photo forum helped here), but the top looks like a bigger deal. Anyone with experience glassing against gravity? Would appreciate any tips.Sorry for the long post (my first) and I thank you all in advance for the help.

 

[clay wright]

call me

Josh,I just completed the same job on my '76 O22, but the repair was on the coach roof under the mast step. The balsa core was water soaked and had compressed under the mast step. I made a very satisfactory repair, which I extensively reported in this forum a few months ago. It has dropped out of sight, and I cannot retrieve it through the search function. I don't have the time to type it all again, but you are very welcome to call me at home and I will be happy to relate my experience. (509) 455-7439 - I hope I am not breaking any forum rules by putting my phone number here! I am on the West coast, so there is a considerable time difference. Happy to hear from you...

 

[JoshGray]

Thanks, new core?

Thanks for the response, I will probably give you a call in the next few weeks. I will be doing the same thing with the mast step. What did you use for the new core? Did you use thickened epoxy to fill in the gaps in the new core? If so, what type of filler? I believe that the '76s had a different mast step than mine (a 73). Mine has an aluminum mast hinged type step that is supposed to have one large bolt down the center and two screws for proper alignment. This setup has since been replaced with three small bolts, I am (hopefully) going to return to the original installation. I am interested to know how you made sure that the mast step was level. Since I will be doing this work with the boat on a trailer instead of in the water getting the boat properly leveled is an important consideration. Thanks again, and you will most likely hear from me soon.

 

[clay wright]

briefly

I decided not to use balsa as it couldn't be found in small quantities and it could not be found locally. A closed-cell rigid foam product called Klegacell was expensive and also could not be obtained in small quantities. I used marine quality plywood that was void-free in the general deck area. Under the mast step I used solid fiberglass mat to prevent future compression. I bedded the whole works with epoxy thickened with a cellulose fiber, so that all the wood is thoroughly encapsulated (may as well be entombed). I did the work on the trailer too, thought it was an advantage as far as level goes 'cause the boat couldn't rock or list. Just use a spirit level on the trailer. I double checked by running a straight edge between the companion slide runners. I modified the mast step to accept four screws instead of three; the original third screw ran into the cabin bulkhead after I relocated the mast step, which had been mis-located by the factory 4.5" ahead of its proper placement over the compression post. It was a busy three weeks, happily I didn't lose the entire season!