Fixing Another DIYers Bass Boat

[Treyhumphrey775]

I picked up a 1996 Nitro Savage 884 that was someone else's project boat. No judgements, but is a bit of a mess. He sanded through and silvered the metal flake, then sprayed auto clearcoat with a yellow tint. I spent a week scraping it all off and am down to the silvered metal flake. No real issues there.

After pulling the carpet, I noticed quite a bit of fairing built up under both consoles, so I got to work removing that. After about 6 hours, I'm down to his fiberglass fix, which doesn't look too bad.

My real issue is there is a 2" gap where he cut and replaced marine ply, what is the best method to bridge that gap from his fix to the original boat deck? And please don't say "spackle fairing", I despise that stuff. I also need to know how to best buildup the bottom left corner of the first pic, for some reason the fiber has a nice slope to it and doesnt line up with the original deck.

 

[Chris1956]

If it is all solid, fill the voids with poly putty or chopped glass and resin, and cover with cloth. Fill the weave of the cloth with resin and install new carpet.

 

[kcassells]

Pretty odd area to work with so here is my suggestion.
You could use marine foam 2# to fill voids. Sand back to below flush. Use epoxy or poly after sanding to filled exposed/sanded cells.
You could skim coat with some pb to level out.
Next lay glass over to bring flush. At least 2 layers, each layer 3" larger than prior.
Sand and fair out. There are other higher density foams that are used for structure.

Urethane Foam , Expanding Marine Polyurethane Foam

Wholesale/retail sales of composite and fiberglass materials, including epoxy, adhesives, carbon fibers, urethane foam, urethane casting rubbers

www.uscomposites.com

 

[Scott Danforth]

Looks like too small of a floor was used.

 

[kcassells]

Like Scott said... crappy floor replacement. That being said since that looks so sad I would be concerned about the quality of the wood under the deck.
Stringers and bulkheads may be compromised.

 

[Treyhumphrey775]

Like Scott said... crappy floor replacement. That being said since that looks so sad I would be concerned about the quality of the wood under the deck.
Stringers and bulkheads may be compromised.

I scoped underneath the deck and pull 4 core samples and the stringers seem to be OK. I can't quite figure out why he decided to replaced the deck underneath each console. I didn't find any evidence of rot.