This summer, I finally tackled replacement of the rotted core around the mast on my O'Day 32' center cockpit. The POs were elderly, and there had been leakage around the mast, as well as a hatch coaming that had rotted. I rebuilt the coaming out of blue styrofoam a few years back, then put about about 6 ply of glass cloth, and epoxied it thoroughly. I has not leaked since. To do the coach roof around the mast, I used a moisture meter, and found the edges of the core rot. I cut off the top skin with a Fein saw, and removed the wet and rotted core. I replaced the balsa with 1/4" inch mariine ply thoroughly coated with epoxy. I then bedded the marine ply thoroughly with epoxy, then put the top layer of glass back on and bedded it thoroughly with epoxy. I did not do kerf cuts in the ply because the deck there was pretty flat. I used brass flathead screws to help conform the "sandwich"to the slight curve around the mast. I sanded the deck to get it smooth and faired and then covered the repair with antiskid. Now I see the seams of the repair. I'm planning to grind out the offending seams with a Dremel and epoxy the grooves. Any advice?
wood replacement of rotted core
- Thread starter jknappsax
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Not exactly clear how you reattached the top laminate, but it sounds like you just glued it back down and puttied the seam? If thats correct, you wont be able to keep that seam hidden for long. You need to grind a taper across the joint out a couple inches to each side and then re-glass it. The core is not the structural part - its the skins (fiberglass) that give the strength and do most of the work.
Yes. Come do my boat.
I've got what sounds like the exact same job ahead of me.I would think feathering out 6 inches or so in all directions, where is the Don Casey book when I need it.
Wet, that is pretty much what I did, but I did not putty; I bedded it in enough epoxy that it squished above the fiberglass, then I sanded all smooth. I did use a couple of brass flathead screws that I countersunk slightly, so they were encapsulated completely. It looks like I'll be doing some more grinding and fairing.
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