Front deck core replacement bulkhead removal and refit

[Keith-i]

How are you intending to stick the [ply to the underside of the deck ?

I would have thought epoxy with a thickener such as colloidal silica.

 

[Restoration man]

How are you intending to stick the [ply to the underside of the deck ?. low expansion PU foam ?Have you considered doing it in wide strips,say 18" wide - pre glassing the underside completely before fitting , then you only have to handle glass (tape ??)over the joints , much easier overhead than large areas.
Jim

Hi jim I was going to stick the ply to the underside of the front deck with epoxy thickened with cabosil then use the nuts and bolts that hold the winch and cleats onto the deck to pull it up and hold it in place while the epoxy dries , I do really like your idea off pre glassing the underside of the ply and like your say I could then prob get away with just putting some strips around the edges, that’s great idea thanks

 

[DownWest]

I would cut it out just leaving the tabbed flange, you need as much elbow room you can get. Then, after clearing all the soft sandwich, try fit the ply, maybe in two halves, before setting it in thickened epoxy. Use props and wedges to hold it up while it cures, then lay up (literally ) the glass in strips with lots of overlap. Much easier than trying big areas overhead. Using ply is less of a structural sandwich, so the under layup need not be so thick. More to hold it round the edges, esp if you use thick ply.

 

[Boathook]

Do you actually require a cored deck as it is in the main accommodation area?
It would be easier to reinforce and or brace the areas where the windlass and cleats are fitted. A lot of this could be pre-made so working upside down would be minimal.

 

[Restoration man]

Do you actually require a cored deck as it is in the main accommodation area?
It would be easier to reinforce and or brace the areas where the windlass and cleats are fitted. A lot of this could be pre-made so working upside down would be minimal.

That’s what someone did before as a bit of a band aid with bits of wood and bits of off cut aluminium checker plate ,The problem with doing that is the core is always compressing , even if you put massive plate on underneath and tighten the bolts , the core is constantly rotting out, the deck fitting get loose again and more water gets in and the Cycle continues , I’m refurbishing the complete
Boat so nows the time to do it , I made a start yesterday by removing the winch and deck fittings before I remove the bulkhead