New project, re-build a bow deck and rails

[Valv]

I just bought a 2000 Kenner 21ft center console. It was a storm damage and it has a big hole in the left side of bow deck and part (approx 4ft) of rail support is gone (and I mean g-o-n-e).<br />It looks like a simple construction, one piece fiberglass mold (I call it a big fiberglass bath tub ).<br />I have to rebuild the side rail, what is a good method to build sort of a mold ? <br />I thought is I use some cardboard and follow design of existing top rail (shaped like an upside U ), then lay fiberglas cloth, and glass it in. Many layers of this until reached thickness of existing hull.<br /><br />Also how do I apply gelcoat for exterior ? Do I have to apply it as first layer, or I can wait until it's all done, and apply it on top ?<br /><br />Thanks for any help <br /><br />Val

 

[JasonJ]

Re: New project, re-build a bow deck and rails

I would probably use wood, like 1/2 ply and affix it under the fiberglass, extending under the good portion of the rails. I would then grind a taper on each end, about six inches of taper and use cloth and mat in alternating layers to build up to desired thickness. Sand even with rest of rail, and paint or gelcoat entire upper deck so it is even and matches. The wood would be left under the new glass to add strength. Others will probably offer better advice, but its all good....

 

[Valv]

Re: New project, re-build a bow deck and rails

I agree with it on frond deck, but on sides it is not very thinck glass, approx 1/2", and just 4" wide.<br />The shape looks like an upside J coming from hull (I should attach pictures), I will do it later today.

 

[SCO]

Re: New project, re-build a bow deck and rails

can you access that j part from the inside or only the outside?

 

[SCO]

Re: New project, re-build a bow deck and rails

Assuming can access outside only, grind bevel around the hole, then fabricate the outside shape in wood, then using mold wax, coat the wood part(now removed from the boat), and lay up glass to it w epoxy resin, thin but enough to hold shape. Id put a rim around hole on the inside then recess the new piece to the rim then lay up to that(overlapping to the bevel you ground in till more than flush with outside, then grind to contour. Anyway, thats what I would do. You need to get crabbaits opinion on this.

 

[Valv]

Re: New project, re-build a bow deck and rails

Ok, here's the pictures:<br /><br /> http://www.kvesurplus.com/Boats/kenner1.jpg <br /> http://www.kvesurplus.com/Boats/kenner2.jpg <br /><br />Let me know what do you think.

 

[SCO]

Re: New project, re-build a bow deck and rails

I didn't have that envisioned right. That's out of my league, but, I would make a 1/4 ply cutout fit to the stbd side of the boat, turn it over and wax it, tape it to the hull and tack that existing side rail to it to get the shape right, then glass w plenty of overlap on the deck. Later you could chip the plywood out with a chisel, and glass on the underside. The big gash into the deck plywood needs some thought. Good luck.

 

[SCO]

Re: New project, re-build a bow deck and rails

I didn't have that envisioned right. That's out of my league, but, I would make a 1/4 ply cutout fit to the stbd side of the boat, turn it over and wax it, tape it to the hull and tack that existing side rail to it to get the shape right, then glass w plenty of overlap on the deck. Later you could chip the plywood out with a chisel, and glass on the underside. The big gash into the deck plywood needs some thought. Good luck.

 

[Kenbo]

Re: New project, re-build a bow deck and rails

Valv, You have quite a job ahead of you. The pictures help out quite a bit, but what is the condition of the hull in that area? With damage to the deck structure like that, you might want to check the hull for delamination and cracking. In any case you will probably want to get to the inside of that bow platform to reinforce/repair the inside of the hull on the port side. As far as a surface to lay-up over, you might be able to use some c-flex to get the shape you want and then do your layup over it. I've never used the stuff myself but here is a couple of links about it. http://www.bruceroberts.com.au/building/methods/c-flex.htm or http://www.glen-l.com/supplies/cflex.html <br /><br />Once you get the hull and side rail repaired, repair of the bow platform should be easy by comparison. As far as gelcoat goes, it can be sprayed or brushed on after completing your layup. It will take several coats and a wax additive should be used to allow it to cure properly. Hope this helps. Good Luck!!

 

[snapperbait]

Re: New project, re-build a bow deck and rails

OUCH!!! <br /><br />To repair the side I would use some masonite or 1/4 plywood covered with wax paper and screwed to the side to back up the fiberglass on the outside of the hull... Grind the glass back like Jason said, and lay it up against the wax paper covered wood, from the inside of the boat...<br /><br />For the top "J" part, I'd use plywood to form it up as best as you can, then (same as the side) lay wax paper over the plywood form to keep the laminate from sticking to the wood...<br /><br />Get the whole damaged area formed up, then glass the entire area in one shot...<br /><br /> Once the glass has cured, remove the wood backing and screws, and fill the screw holes with putty.. Then on to the deck repair, and gel coat..<br /><br />Might wanna check out some books before ya start... A good one is "The fiberglass boat repair manual" by Allan Vaitses..

 

[jomac]

Re: New project, re-build a bow deck and rails

Valv I would start by getting by cutting out the forward deck area cut out then attack in two steps 1 as the others have said us something easy to form I've used formica before works pretty good, shape it then glue or clamp it to the hull repair that damage first then u can use regular canned foam! just use cardboard and tape to close in the bottom edge of the gunnel fill it up let cure for awhile then simply file it to the shape u need to form to gunnel then glass the whole repair over at one time. pull the foam out feather out the rough edges then glass the outer portion hull also good luck! U may try contacting Kenner on a 2000 u may talk them into selling you a patch panel that u could slice in again good luck

 

[Valv]

Re: New project, re-build a bow deck and rails

Ok guys, thanks a lot for the good replies, I will tackle job very soon and post results with pictures.<br /><br />As the Terminator says.... I'll be back !!!