$32.95. To repair the deck, I will cut back the damaged area(s) until good, undamaged fiberglass is exposed. This assumes that a crack or scrape isn't all the way through the laminate. Give yourself a 16th of an inch of unmasked margin around the scratch, gouge or hole. Applying fiberglass skin Here is a basic step-by-step process for applying fiberglass skin. The forestay came down but mast stayed up and now that I have sailed the boat a couple of times the deck has obviously delaminated where chainplate goes through. After the repairs are completed, some boats remain crack-free for years. a caulker's reefing iron or a sharpened and bent file. The simple solution to core breakdown is to open up the affected area, remove any water, rotted or delaminated core, and epoxy in a replacement core that re-establishes the laminate strength and structure. Dewax. When the two side pieces were a perfect fit, he measured the center piece, cut it out of in plywood, and routed the forward end so that it fit under the lip of fiberglass there. Clean off the excess resin with a putty knife and put it back in the container to "kick." You'll want to keep going until you are into solid core. Sail boats, due to their rigging, are relatively more influenced by this aspect. 12-302: Trailer 2300/2800 Plans: For boats 16' - 22'. 4. Fiberglass Boat Repair Kits contain 8 pre-measured packets of WEST SYSTEM 105 Resin and 205 Hardener, fiberglass . This boat also had access ports installed by the previous owner without sealed hole edges. If the upper and lower fiberglass layers are structurally sound, the core can be repaired with injection. Mix resin. Mask the edges with tape. Ports or no ports, water left in the hull can evaporate and penetrate the inside layer of fiberglass and damage the foam layer. Once the epoxy is hardened, remove the tape. the professional fix is to cut back the unbonded areas and reglass with epoxy and fiberglass. Re: fiberglass delamination? You should silicon all leaks in your hulls, drain them after each sail, and remove the drain plugs prior to storage. Trim the syringe tip as necessary. Fittings are, on same boats, glassed to the deck and they require an accurate inspection because a delamination can produce the chain plate shifting which can be noticed, on the most severe cases, by the continuous loosing of shrouds. Higher-quality materials typically require higher costs, with fiberglass and gelcoat repair costs reaching as high as $450. Most also contain some cored laminate, as this is the most effective way to decrease weight in a fiberglass boat while also increasing its strength. 4) Treat the gutted area and surrounding wood with CPES. If you have dry rot when you drill your holes, lightly spray your newly perforated deck down with water and in 30 minutes, inject your deck." waikikin, Aug 20, 2015. Soft hulls are caused by the foam and fiberglass layers becoming seperated or delaminated. That certainly does not look good. Worse, those visions may be equated with an unsalvageable hulk lying in the mud of a river bank. Be careful not to gouge the fiberglass. Cutting away the fiberglass skin exposes rotten balsa core. Mark the position of the frames by drilling as described above. I'll make the Backing Laminate. Once in Colombia and once in Panama, we carefully removed sections of the teak, cut out a section of fiberglass, repaired the core, and then put it all together again. #3. Materials List in the link below I'll also cover filling in holes and other defects using epoxy resin with. When this happens, it's a very definite sign that the stringers need to be repaired. If the deck core has been left flexible long enough, the flexing can fatigue crack the fiberglass under and over the core. Cut out the damaged area of the roof with the jigsaw. I was thinking that the expanding GG will fill the void and minimize the "dented" look (as if I did the same thing with epoxy and a weight). This can be done either from the topside or below deck. Anyone ever put GG into an epoxy syringe? Trowel the epoxy flush with the surface and remove excess epoxy before it begins to cure. Inject GG into the delam area. 6. lay a piece of wax paper across the repair and place something heavy on top of it. Push the stringer in position with firm hand pressure. This includes pre-cutting the core material and all reinforcement plies to fit within the taper you've prepared as you've readied the surface. After gelcoat removal, sand the fiberglass laminate with 80-grit sandpaper. Detailed instructions show users how to do it right. The original fiberglass tab should be trapped between the wide fender washers and the bulkhead. I''d inject polyester resin to fill the void. mmiller wrote: Hulls - Soft or Delaminated hulls on older boats. The area was small when they bought the boat (some time back) and grew a bit to about 3' by 3' area flexing . Brown Spots If there are brown spots on the stringers, these will almost certainly be water that's weeping out of the stringers. Luckily so much of the deck had delaminated that most of the core material popped right off. Once turned on use the bits shaft as a guide and work your way around the hole moving up and down and around the circumference of the deck hole to clean the core material from the the skins and make a nice, even, round cavity for the epoxy to seal the deck. Assuming you have some solid spots, you can hear a solid tap, tap, tap with each blow of the hammer. Tape It Off. 04-26-2012, 01:19 PM. In speaking to the fellow who makes the product he says the compressive strength is between 200 and 400 PSI depending on how much water is in the core. The top of the mast was repaired but I have discovered that there is damage to the deck because of excess pressure on forward side stays. One of the most common methods is to perform the repair from the outside, peeling back layers of fiberglass and replacing the core material. Suck resin into the syringe and squirt it throughout the delammed and drilled area until it is oozing out of all of your holes. Wooden canoes or clinker construction is similar. Seems the best approach is to come in from the stateroom and fix the problem area from underneath. Step 1 Take the resin and hardener mixture and apply to the prepared bonding surface and the stringer. Here are the steps in repairing the RV . Less water equals a denser and stronger closed cell foam. 5. This kit contains eight packets of West System 105 Resin and 205 hardener, fiberglass fabric, adhesive filler, fairing filler . Mix epoxy Add 409 Microsphere Blend to a WEST SYSTEM epoxy Make sure it's mixed to a ketchup consistency and then load into a syringe. 2) Dig out bad wood with a hook-like tool (i.e. Is the foam soaked in the boat. Finish by wet sanding with 220-grit. Roll on a minimum of three coats of WEST SYSTEM Epoxy to seal the fiberglass before applying a finish coat of paint or gelcoat. 5. Then re-glassing and spraying new gelcoat and non-skid. RV delamination is caused by moisture that penetrates between the outer layer and the substrate resulting in weakening the bonded layers. Sand the area smooth. Video unavailable Watch on YouTube Watch on Previous posts Fiberglass delamination can be fixed by drilling small holes into the fiberglass surface of your boat. Its a structural issue on the walls and fixing it to be as it was earlier may. If your part features a sandwich core material, cut the core first to fill the deepest hole. Step 1. Boat hulls, of course, are not built that way, although they could be. Cover undamaged areas of the hull close to the area to be repaired with newspaper. LLE is a thin adhesive epoxy and can be further thinned with a small amount of ECS if necessary. Repairing the deck of this boat was done from inside the cabin because of the difficulties replicating non-skid. Questions for the repair: It can absorb small amounts of water, but water won't pass through it in a way that will cause problems in a trailer boat. Part 1 of a two part video on rotten balsa core replacement on a valiant 40, using a break through material that is bound to change how soft decks are repair. Replacing the damaged balsa core involves removing the fiberglass skin to expose the core. We cut enough to do both sides of the bulkheads with two layers of cloth, then set them aside. Fiberglass Boat Repair & Maintenance. You can inject the materials you want, such as resin or other fillers, and a west system that dries and becomes solid rock protecting the fiberglass surface of your boat. Jun 7, 2009. The word "delamination" causes instant visions of a good old boat coming apart at the seams. This method is unsatisfactory for the following reasons. Clean out or vacuum out loose debris. Very few boats, however, are made entirely of solid glass. 1. park the RV someplace where you can lean the 2x4's against the delaminated area and wedge them into firm ground or pavement while leaning against the RV. Step 9: Sanding. If your boat is all fibreglass screw or bolt and resin the stringers back down, sand and clean the whole soft area and glass it up with a good quality woven mat, remove the screws and fill the holes with glass fibre and resin. This product is attracted to moist environments, and water helps in adhesion, expansion and curing. Heat can damage the resign and could lead to bonding problems later. Step 2 Take the first piece of your fiberglass skin, which is the largest and place it over the stringer and apply the resin and hardener mixture. I will cut two pieces of 8 ounce fiberglass cloth, three inches larger than the hole(s). Call us today at (856) 393-7720 to learn how our boat craftsmen could get you the best fiberglass boat repair, at the right price, with superior service right here in Riverside NJ! Boating Magazine. Cut away the old ply then proceed as if building from new. Use a small screwdriver to lift the glass up to allow the epoxy to flow under the fiberglass. A . 16-037: How to Fiberglass a Boat Book & DVD Combo: Save $$$ on this Book & DVD Combination! Is there a stringer behind that break? RV fibreglass delamination is a bad sign and it . And good luck. Use the rotary tool and a pointed grinding bit to dig out the damaged gelcoat. Allow the epoxy to cure thoroughly. Several technical publications recommend an "easy" fiberglass delamination repair which involves drilling a series of holes through the top skin of the deck and forcing epoxy resin into the holes until it fills the void and emerges from another hole. Tape off the area around the damaged gelcoat. Cored decks have been standard since the earliest days of fiberglass boat production; they help decrease weight well above the waterline . Please resize your pictures to 640 x 480 for the forum so they accomodate the members who do not have high speed connections. Drill 6mm holes, 25mm apart and about 75mm beyond the delamination area. This is a highly recommended material among the savvy boaters and sailors. You could also Request A FREE FIBERGLASS BOAT REPAIR QUOTE on our website or to request more information. A resin is used to fill the blister and a new gel coat applied. 3. drill several small holes throughout the delammed area. It's done using many small air tubes inserted into 1/4-inch holes, ideally drilled in areas that are unobtrusive and easy to repair, maybe on the underside of a chine. I''d avoid epoxy for this injection in case the void is too deep causing excess heat build up with an epoxy that may break the surface with extreme pressure as the epoxy ''kicks''. After sanding, make any needed repairs to the area. The wainscotting strip or perhaps or roof strip can come off. If the fiberglass does not show stress cracks or obvious hydrolysis (blisters or milky looking fiberglass), it will be fine. Not all boats are built this way, but the vast majority of Beneteau sailboats are constructed with a cored deck. This is normally correctable. 11,525. While nothing is waterproof, fiberglass for all intents and purposes is. The 105 K Fiberglass Boat Repair kit contains enough epoxy, fiberglass, and fillers to complete repairs to cracks and holes, gelcoat blisters, delaminated cored panels and more. Remove something to get access to behind the delam area. On top of this I spread another layer of filler and laboriously block-sanded it until level. I covered the deck with five more layers of fiberglass cloth and epoxy resin, repainted it and reinstalled the deck hardware. the cockpit pedestal/steering wheel, drain and diesel fill cap. Brace or tape the stringer in position as necessary. If you fail to remove the wax first, grinding will drag it into the bottom of the scratches and weaken the bond. This coating is used to protect your RV from the elements, but the elements can tear your protective coating over time. Shape the squeezed out epoxy into a fillet. Carefully mask around the edges of the fiberglass boat repair area with two-inch-wide 3M ScotchBlue Multi-Surface Painter's Tape No. Any delamination, especially on the deck, should be repaired as soon as you notice it. Finish the area with gelcoat or paint. 3. Cut inch of fiberglass mat for each hole and you would need two layers of fiberglass cloth to cover up the soft areas. Don Casey, one of the boating experts for the Boat Owners Association of the United States, recommends beginning with "two layers of 1 1/2-ounce mat," then alternating the mat with 6-ounce fiberglass cloth. IT was fairly severe but I was able to get this fixed so it is undetectable and solid now! It simply doesn't do the job, as water will go through it. The deck is composed of gelcoat/glass/plywood core/glass. (You can fill it later with Epoxy Filler.) Once the area is blended, sand the whole patch to flatten. I then cut -inch polyurethane sheets into 4-inch squares and set them into the deck in a thickened epoxy filler. Cut a strip about 1-inch wide and 15 inches long, and cram it into the hole using a blunt instrument, such as the dull end of a cooking skewer. Use 100-grit paper to remove any bumps or ridges. Apply the mixture with the flat end of a mixing stick. For medium sized repairs, the West System Fiberglass Boat Repair Kit 105-K offers the right epoxy, fiberglass, and fillers to complete repairs to cracks and holes, gelcoat blisters, delaminated cored panels, and more. Bevel the edges around the damaged area and grind away the damaged part down to the fiberglass. I found a product called injectadeck which claims to fill the voids of the rotted core, seal things up and give solid decks again. The epoxy mixture should squeeze out of the joint. When you hit a spot that has delimitation or rot, the tap turns to a hollow thud sound. My boat too has a liner independent of the three-layer construction. Let set, prep and apply normal glass deck patch. Carefully pry off the skin and use a sharp chisel to remove rotten or delaminated core. an alternative would be to pour/pump/feed a solvent free, low viscosity, bonds to damp surfaces, epoxy into the void between the glass and the wood. Tighten the pre-set screws enough to draw the bulkhead and fiberglass tab together and squeeze out some epoxy resin from the gap. Apply a liberal amount of thickened epoxy/404 High-Density or 406 Colloidal Silica mixture to one side of the contact area. These parts may also need to be carefully pulled away from the walls if attached. Instead, modern fiberglass boat hulls relay on a limited number of major girders and frames. Note all the test holes drilled to determine the extent of the problem. To be honest, fixing or repairing delamination on a camper is not for everyone. Large areas with stress cracks may be repaired with injection but I have not done that so I cannot predict the success. B Badfish From the underside you can see the plywood core through the glass, and it looks the same as the surrounding wood, which makes me think this is delamination, not wet core. The skin can be extremely thin because the frames are so close together. Weakened or Soft Decks. Look at the molding locations to locate screws or nails underneath. PS. Pre-cut the fiberglass matting and cloth you'll use to fill the hole, using scissors. Sand using 180 grit sandpaper to blend the repair area into the existing part of the surfboard. If your deck core isn't rotted away or wet, but just delaminated from the fiberglass skin- then just filling with epoxy will be a permanent fix, without any glassing. The typical repair cost can vary from $75 to $110 per hour, a price which includes material costs and labor charges, but repairs that need more material and longer labor can cost up to $350. The following video shows how easy it is to repair small plywood boats by replacing panels on a boat which, has been built over a wooden frame. Go slowly when grinding and sanding to minimize heat buildup on the existing laminate. For that, use a mixture of gel coat resin and apply this with a brush on the areas you have applied wax previously. Sand the rails by hand as the epoxy there will be thinner than other parts of the repair. ie. Deck weakening is caused by moisture which rots the organic core that supports the fiberglass. Drill through the skin and about of the way into the core. When I tap the deck to sound it out the area that sounds hollow is fairly large (maybe 2 sq feet) and I know the best solution would be to open it up and replace the core. I've had my '69 Ericson apart just like yours for substantial areas of core repair done from above, and can confirm that the bottom layer of the sandwich is much thinner fiberglass than the top, and not uniformly laid, probably one cloth's thickness in spots. Performing a Tap test and listening for a hollow 'thud' sound. Notice the ingenious way that the repair is supported by spring loaded shower rods. - this is how 90% of delaminated decks are fixed. Depending on the extent of the damage an entire section of the ceiling may need replacing. 25,897. The first step to laminating the repair patch is pre-cutting your patch materials to fit the repair. Re: Exterior hull delamination, easy fix? Inject epoxy Make a few passes and suck any dust out with a shop vac. 3) Allow interior to dry, or blow-dry. This can be caused by heat, repeated compression (walking on) or other factors related to materials and age. $45.00. This eliminates the challenge of wetting the glass and getting the epoxy clear to the bottom. 6 1 Repairing delaminated soles and decks 40 6 2 Installing a teak deck 42 7 Installing Hardware 7 1 Bonding fasteners 45 7 2 Bonding fasteners and hardware 46 . Disassemble and remove all fittings in the floor. Using the multiple hole technique. Drill a hole to get the jigsaw blade into the ceiling. Drill a small water outlet hole at the bottom of the transom. #4. Starting at the high-end pour Layup and Laminating Epoxy (LLE) into the holes over the plugs. Remove all of the old core and fiberglass material, leaving just the top fiberglass skin. This step was by far the least fun. Fatigue Fiberglass boats endure several sources of stress and the hull will lose its strength due to the impact of waves and vibration. Probably a simple ''void'' or gas pocket that formed during layup - a fairly common occurance in older boats. 2090. RV delamination occurs when the layer of fibreglass, laminate, or gel coat on the exterior of your recreational vehicle begins to bubble, tear, or peel away from the shell. 3. I used a oscillating tool to carefully cut around the edge, then peeled the glass and core off. We used 3/8 stainless bolts to fasten these together, but drilled 7/16 holes. In my case, since the deck was getting new non-skid anyway, the repair would be easier from the topside. Using Vinylester resin I will pour the resin over the 1st cloth on the wax paper, and then repeat with the second piece. I drilled a few holes from below (not going through the top skin) to let the core dry out and find the extent of the damage. WEST SYSTEM, 105 Epoxy Resin, 205 Fast Hardener, 206 Slow Hardener, G/5, . The chain plate is not attached to a bulkhead. With the bulkheads still in place, we drilled three holes through the bottom of each bulkhead and through the floor frame. Don't rely on a gel coat for protection. How to Fiberglass a Boat DVD: Learn how to fiberglass the easy way, by looking over the shoulder of an expert who is working on actual boats . Since this O'day 30 had an exterior that was in prime condition, we chose to repair the deck from the inside instead. Wipe up excess that comes out the holes. You can depress the deck about 1/8" in that damaged spot until it hits the core. Hull Design Defects Part I. Cut the top layer of the existing fiberglass laminate and peel it off Scrape out the old wet deck core Prop up the bottom half of the fiberglass floor from below until level again Lay down fresh foam core Most boat decks are wet rotted and perfect candidates for this product. Gelcoat Repair. May 4, 2009. The original fiberglass will have traces of mold release on the outer surface and wax surfactant on the inner surface. This is a friends boat that is showing some delamination of the fiberglass over the port side of the deck on the bow. Epoxy plus Fiberglass Cloth Fill the hole with neat epoxy. Take a small hammer and tap every 6-8 inches around the deck. Step 4: Put The Finishing Layer Now that the holes are filled, you have to work on the entire deck. Delaminated fiberglass may conjure up images of free-falling straight through to the bilge but it need not frighten the most resourceful among us. 4. To repair a blister, your boat technician will typically need to remove the gel top coat and the fiberglass substrate. When it started leaking in yet another place, we decided it was time to remove the teak entirely, repair any damaged sections of the core, then fare and paint the decks. Before grinding, always wash the area around the hole thoroughly with a dewaxing solvent. Using a grinder, Dave tapered the edges of the boards where they met the remaining laminate. The patented Dryboat method injects "desert-dry" air into wet sections of coring to drive out the moisture. 2. Using a circular saw, shallow cuts were made just deep enough to cut through the top skin to . Grind a scarf joint around the repair area to a width of 12 times the thickness of the skin, about 1.5 inches for 1/8th-inch skin.
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how to repair delaminated fiberglass boat deck