Filling a gap in core material

gmach

Recruit
Joined
Nov 15, 2025
Messages
1
I am in the process of replacing rotten plywood core on a section of the deck on my 95 Sea Ray 230 Sundancer. The wood is coming out and 1/2 inch, 20.lb density Coosa is going back in. I'm going to bond the Coosa to the existing fiberglass with structural epoxy (mix of milled fiber and cabosil), then glass over the Coosa with 2 layers of 1708 biax and vinyl ester resin. There is about a 2 inch gap between the edge of the Coosa board and the vertical surface of the fiberglass I will be tabbing to. Would it be ok if I just filled this gap with thickened and reinforced resin?, or should I fill with a strip of Coosa.
 

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bakerjw

Petty Officer 1st Class
Joined
Apr 3, 2013
Messages
338
I'd cut a piece to fit in there with perhaps an 1/8" gap around the edges. Mix some thickened resin and press flush. Cover with biax and you should be good to go IMHO.
Can also do a partial fill with thickened resin and form wetted out biax into the void.
 
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