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Pierre · Joined: 10 Sep 2008 Posts: 7 Location: Quebec City

My E32 1981 deck has many soft area, I mean moisture.

What is the best method to dry or repair the deck ?

Is it existing a method to do the work by the inside of the cabin to avoid the destruction of the anti-slip deck surface ?

If you know a good web site about this subject, please send me the address.

Thanks for the help.

Pierre

Bruhmuller · Joined: 30 Jul 2007 Posts: 2 Location: Lake-Champlain

Bonjour Pierre

I would like to follow this thread because I might have the same problem.
I have an Endeavour 37 at Lake Champlain. The deck is not soft but some areas as to my surveyor are to be closely watched.

J'aimerais bien suivre cette discussion car je crois avoir sensiblement le même problème. Le pont n'est pas mou mais je doit être vigilant.
J'ai un Endeavour 37 au Lac-Champlain.

Pierre B.
Endeavour 37

FastFred · Posted: Wed Sep 24, 2008 5:06 pm Post subject: Soft decks

We had a similar problem on our E40. After weighing the options (attempt to inject epoxy into the plywood core, or 'pour' thinned epoxy into the cracks), we went with 'Plan B': Cut out the cracked and spongy deck sections and replace them. The fiberglass beneath the core was still good. Most of the core was actually good. The soft spots were where the deck had separated and 'lifted' from the core. A fiberglass mold was made over a good section of the 'berber carpet' non-skid pattern on the coach roof, and that was then used to make new fiberglass sections for the cut out parts of the deck. I now cannot see where the new sections begin and the original deck portions end. It was that good of a job.
Pricey, but good. :<O
best regards,
Fred

Pierre · Joined: 10 Sep 2008 Posts: 7 Location: Quebec City

Well, it seem to be a big job.
What is the method use to mold the non-skid patern ?

FastFred · Posted: Thu Sep 25, 2008 10:00 am Post subject: Deck non-skid mold

The technician thoroughly cleaned a nice section of the non-skid deck pattern, applied 'mold release' chemical, then made a mold by laying on a few plys of epoxy-impregnated fiberglass cloth. When it was dry, it was removed, mounted on a piece of plywood and a similar process was used to make the replacement deck sections from that mold. Almost easier to do than explain. I kept the mold in case I ever need to replace more deck sections. Anyone who has ever made a fiberglass mold could do it...you don't need a high-priced Boatwright.
good luck,
Fred

Pierre · Joined: 10 Sep 2008 Posts: 7 Location: Quebec City

OK, for the pattern molding operation.
What it's not clear is the way to rebuild the deck.
We have to dig into the deck to remove all rotten material (gelcoat, fiberglass and plywoodcore) until reach the lower fiberglass layer (the one we see from the inside of the cabin). Then we rebuild it.
Do we have to laying on a few plys of epoxy-impregnated fiberglass cloth on the mold first and trying to fit it in the hole after ?
Or we rebuild directly on the existing fiberglass layer and trying to put the mold over it after ?

I think I will learn a lot about composite application technique on this project.

bobfnbw · Joined: 10 Aug 2008 Posts: 75

Get this old boat by don casey, or his newest one, the Complete isistrated book of saiboat maintaince.

http://www.amazon.com/exec/obidos...ooks&field-author=Don%20Casey

FastFred · Posted: Mon Sep 29, 2008 3:06 pm Post subject: Deck repair

Pierre,
If your mold pattern is at least as large as the section of non-skid deck you want to replace, it is an easy task to cut the new piece that comes off the mold to fit...especially if you have cut the old deck back to one of the smooth non-skid portions. After you have rebuilt the core, bevel both the new piece of fiberglass and the deck where they join, (it makes for a better bond if the new overlaps the old slightly), and epoxy it to the deck core. With a little grinding and filling it is then simple to 'fair' the new section to the old. It won't look like a patch if done properly. Cover it all with gel coat &/or paint. I like Awlgrip.
http://www.awlgrip.com/awlgrip_pages/about.htm
This is one of those jobs where a skilled fiberglass technician can really make your life less unpleasant. I have not seen this process described in a text (as referenced above), but I'm sure the task is not that unusual in a competent boatyard.
:<)
Fred