Currently trying to renovate a 67' Meridian (25') .. here is my most recent headache. Due to poorly bedded deck hardware (previous owner!), the layer of balsa that is glassed underneath my fore deck is all wet and delaminated from both the topside and inner skin. It's not everywhere, but a significant amount of it is ruined. I have removed a small sample portion using both an angle grinder w/cutting wheel (for inner skin) and a peice of sharpened sheet metal for the balsa. Unfortunately, this process is SLOW .. and it looks like the majority of the balsa has to go. Any suggestions for speedier removal of this compromised material? Any help greatly appreciated.
Rotten balsa layer below deck .. need help :(
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Would like the details if ..
.. during the course of the removal you found an efficient means of doing so without damaging the deck above. It looks like I have no choice but to do this if I want this boat structurally sound again. If I didn't like the hulls classic lines so much I would can the thing, as it was donated to me in a (very) sorry state. But I'm stubborn. Any details that may help would be more than appreciated.
.. during the course of the removal you found an efficient means of doing so without damaging the deck above. It looks like I have no choice but to do this if I want this boat structurally sound again. If I didn't like the hulls classic lines so much I would can the thing, as it was donated to me in a (very) sorry state. But I'm stubborn. Any details that may help would be more than appreciated.
Repair Rotten Core
I worked on a Cheoy Lee 46' with very similar issues. We drilled 1/4" diameter holes on a 3" grid pattern from the inside, through the liner, through the wood, but not through the deck skin. Let the boat sit in indoor, heated storage for 3-4 months to dry out as much of the wood as possible, then filled each hole with West System Epoxy working with a syringe. The epoxy will soak into the rotten wood making it solid, and also create a bridge from the inner to outer skins. The combination made the decks solid as new again. The process is not easy, but it worked.
I worked on a Cheoy Lee 46' with very similar issues. We drilled 1/4" diameter holes on a 3" grid pattern from the inside, through the liner, through the wood, but not through the deck skin. Let the boat sit in indoor, heated storage for 3-4 months to dry out as much of the wood as possible, then filled each hole with West System Epoxy working with a syringe. The epoxy will soak into the rotten wood making it solid, and also create a bridge from the inner to outer skins. The combination made the decks solid as new again. The process is not easy, but it worked.
The secret to success in this business is tools.
A right angle grinder with 25 grit sanding disks is essential. A rotary power tool like a dremel on steroids is very helpful. A shop vacuum is needed. Scrapers and protective clothing, dust masks, gloves, goggles are must haves. Now you start the mean part. With a carbide burr in the rotary tool cut the interior fiberglass that you want to remove. You don't need to cut very deeply just through the skin. Then scrape out the rot and with a course disk grind the area clean. Grind the edges of the remaining fiberglass to a long taper exposing some of the old core around the edges. (if you find rot keep going). Next you can start putting things back. select a core of your choice, I used Airex core scored for flexibility. this is set in corebond adhesive and then glassed over. Applying fiberglass over head is the meanest work I have ever done but this is how. Cut pieces long enough to span the repair and roll them one at a time on a cardboard tube. Mix your resin and with a paint roller wet the place where you will put the glass. next with a full wet roller at hand start the glass on one edge of the work area and as you slowly unroll the glass apply the resin filled roller keep everything close to the work don't allow any air gaps and get all of the edges stuck in place. then with an air roller compact the glass resin packet. Wallpapering the ceiling in a closet is good practice. You will apply at least four layers of glass and resin. when it has cured you can start grinding out the sharps and bubbles. More later after you ask some questions.
A right angle grinder with 25 grit sanding disks is essential. A rotary power tool like a dremel on steroids is very helpful. A shop vacuum is needed. Scrapers and protective clothing, dust masks, gloves, goggles are must haves. Now you start the mean part. With a carbide burr in the rotary tool cut the interior fiberglass that you want to remove. You don't need to cut very deeply just through the skin. Then scrape out the rot and with a course disk grind the area clean. Grind the edges of the remaining fiberglass to a long taper exposing some of the old core around the edges. (if you find rot keep going). Next you can start putting things back. select a core of your choice, I used Airex core scored for flexibility. this is set in corebond adhesive and then glassed over. Applying fiberglass over head is the meanest work I have ever done but this is how. Cut pieces long enough to span the repair and roll them one at a time on a cardboard tube. Mix your resin and with a paint roller wet the place where you will put the glass. next with a full wet roller at hand start the glass on one edge of the work area and as you slowly unroll the glass apply the resin filled roller keep everything close to the work don't allow any air gaps and get all of the edges stuck in place. then with an air roller compact the glass resin packet. Wallpapering the ceiling in a closet is good practice. You will apply at least four layers of glass and resin. when it has cured you can start grinding out the sharps and bubbles. More later after you ask some questions.
V, go over to Trailer Sailor or the CSBB and ask
http://bbs.trailersailor.com/forums/trailersailor/index.cgi or http://www.cs-bb.com/forums/CSBB/index.cgi There is a fellow there, CJ, who has saved a Meridian 25. It probably had most of the same problems you're facing.
http://bbs.trailersailor.com/forums/trailersailor/index.cgi or http://www.cs-bb.com/forums/CSBB/index.cgi There is a fellow there, CJ, who has saved a Meridian 25. It probably had most of the same problems you're facing.
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