Re: Deck hatch lids
I have a 1988 25 sportsman that had a soft core over the fuel tank. It was very easy to remove and recore. The origininal core was scrap 4 x4 pcs. of plywood ??? I was originally going to use balsa but ended up using an exterior grade 1/2 ab plywood . No voids or keys.
it was an exact 24 x 48 pc i needed these were the steps: Took 1 day
1)removed section from boat ....it was screwed and caulked down.
DON'T THINK I HAVE TO SAY THIS BUT.....Wear eye protectection cover all bare skin and Wear the best respirator mask you can find! Oh and do this outside away from people you love.
2) Placed section on saw horses upside down, cut out all the bad wood and delaminated fiberglass. The outside skin of fiberglass plus the non skid deck was about 3/16 thick.
3)Ground down the side the bad core was attached to, so it was even and had a good surface to epoxy to. Wipe out with acetone soaked rag
4)coated all sides of my new core with West 105 epoxy so its sealed
5)Mixed west sys epoxy with thickening agents made as thick as a good Marinara. spread out so it covers all the area I had rough sanded down before.
6)lay in new core, picked it up to check coverage than place weight on top to make a good bond. let harden
7)laminate on top of new core with west 105 and either chop strand mat or stiched biaxial cloth .
8)If you penetrate any of the new core make sure you seal with epoxy and use life caulk on hatches and screws.
TIP .... Coat Wax on any gel coated surface you don't want epoxy on. It does drip.
I know a lot of people might not think exterior plywood is a good core but it has to be better than the SH!T Wellcraft used originally, and that lasted 20 yrs in my boat. Just don't make holes in it and leave it unsealed like the Wellcraft workers did.
