EZ-Docks

Kansas City Sailing BlogCalendar

Soft Deck? Cut it out and repair with WEST SYSTEM epoxy!

 

Step #1: Tap all around the deck with the handle of a screwdriver and listen for soft core (dull thud sounds): "Uh oh..."

Sonar deck 1

 

 

Step #2: Get out the chainsaw (or something more precise) and cut out the top layer of deck...

Sonar repair 2

 

 

Step #3: Take a long deep breath and peel off the fiberglass top skin...

Sonar 3

 

 

Step #4: Say, "Wow, no wonder this deck felt soft!"

Sonar 4

 

 

Step #5: Pack your bags with rotten core materials so you can show your friends...

Sonar 3

 

 

Step #6: Scrape and clear out all the rotten stuff...

Sonar 6

 

 

Step #7: Get your new foam core ready ...

Sonar 7

 

 

Step #8: Wet out the newly cleaned surface with unthickened WEST SYSTEM epoxy. Lay out fiberglass mat, saturate with more unthickened epoxy, and then spread a layer of epoxy thickened with WEST SYSTEM 403...

Sonar 8

 

 

Step #9: Place your new foam core on top of the wetted out surface, glass mat, and thinkened epoxy...

Sonar 9

 

 

Step #10: Admire your work...

Sonar 10

 

 

Step #11: Fill in all the gaps on and around the new foam core with WEST SYSTEM 403 (High Density Filler) and prepare to replace the top layer of fiberglass (removed in Step #3)...

Sonar 11

 

 

Step #12: After the deck skin is replaced it's time to grind a channel around the repair so 2" glass tape can be applied and then faired with thickened epoxy...

Sonar 13

 

 

Step #13: The 2" glass tape ties it all together by joining the repair to the deck...

Sonar 13

 

 

Step #14: WEST SYSTEM epoxy thickened with 407 fairing filler is applied to the fiberglass tape in the channel so it can be faired and ready for painting...

 

 

When finished it should look like it did before you started, but be sturdy enough to dance on...

Sonar 13

 

...and rest assured, your boat will now sail fast(er)!

 

 

 

Links to some of our favorite marine industry manufacturers...

Catalina YachtsHunter MarineLaser Performance

HaynHarkeninterlux Yacht PaintsNew England Ropes

RonstanGillLewmarUllman SailsWest System Epoxy