Similar to the cockpit, we knew our foredeck was wet when we purchased Resande. It’s a common issue on old boats where hardware goes through the deck if the owner isn’t keeping up on leaks. We decided to tackle this project in Fall 2021, after hauling out for the season. We’re also not planning to add back our staysail boom. We’ll have a post about how we’re rigging the staysail without a boom in the future. Most of the steps are identical to our Recoring the cockpit post, but we decided to do something a bit different for the high-load areas that have the highest risk of future leaks. As you can see in the pictures, we used 3/4″ plywood just like the cockpit. The difference is we made inserts out of 1/2″ thick G10 fiberglass board and glassed these inserts into the plywood prior to laminating.
The areas we did this in are the high load areas: windlass bolts, new port & starboard cleats, and the staysail tacking point. These areas will all have thru-bolts and will benefit from the high compressive strength of G10 (plywood or balsa core will deflect under a highly tightened bolt).
Resande’s foredeck has a lot of hardware due to our staysail. We aren’t planning to continue using a staysail boom, but we do plan to add a second foredeck cleat. All of the hardware now removed, we start to understand the scope of the water intrusion. After cutting the top shell of the fiberglass off, we scrape out the wet and rotten wood. We used an angle grinder to remove the top shell. Scraping, then sanding down to the lower fiberglass shell to make sure you adhere to something solid when you put the new core in.This is the new core piece. As mentioned before, we added pieces of G10 where the high load hardware is located. Above in the picture is the layout: Staysail will attach in the top insert; the two small inserts in the middle will be cleats, and the large one at a diagonal is where the windlass will bolt through.We used multiple layers of 17oz biaxial fiberglass cloth to build up the 1/4″ difference between the 1/2″ G10 and 3/4″ Plywood. this was on purpose, and we beveled out the plywood so we could build the layers up and larger in diameter.Not shown, but we made relief cuts on the underside to help contour to the shape of the deck. The deck is slightly crowned, so we needed to flex the new core down on the side, we used pieces of wood to help clamp them down as the resin curedAfter the core is in place, we ground the edges to a bevel to make a smooth and seamless transition. Our goal is that this new edge is nearly invisible.As with the cockpit, we did 3 coats of fairing. This step is much like mudding drywall to try to get the seamless transition from the old to the new. We used the West Systems. Fair, sand, repeat until happy.The final layer of fairing we used micro-balloons, which sand even easier for a nice final finish before gelcoat.
We used Total Boat topside paint instead of gelcoat. We decided to go with white and not try to match the foredeck color to the rest of our non-skid. We are planning to paint total boat non-skid in this area when we get a warm, dry day.
We also decided to go with a cleat on each side and not just replace the one center cleat we had previously. We moved the placement of our winless buttons and added a wash-down pump on deck. A final look with everything back in place. Completely done except the non-skid paint.
What do you think? Questions on our process or suggestions for our next project? Leave us a comment below.
On our sail down to Muskegon from Bowers Harbor, we noticed flexing under the helm when steering hard. We knew moisture was high from the survey, but we didn’t think of the practical concern and thought it would be a ‘someday’ project. After that sail down, we knew it was a critical project for the safety of the boat, so it was the first place we decided to tackle.
The area that was wet & rotten was the entire helm area, to just forward the steering pedestal (which we had to remove. The 4 bolt heads aft of the pedestal hold the steering brackets on our Ericson. All the steering hardware had to be removed prior to recoring the deck here.
Chiseling out the rotten and wet core. Our cockpit has end-grain balsa core which does a nice job of isolating water intrusion to close to the hardware. We were able to get all the bad stuff out with a chisel, hammer, crow bar, and anything else that can do some damage. We also found a straight bit on a router set to the right depth can help make this process quicker when you hit the high moisture but still bonded areas.
After the core is removed prep the area: Sand, remove any old fibers or wood, and wipe with acetone.
The final product before the new core. We ended up extending it forward more than our original tapping.
We cut the core to shape, ground down the edges with an angle grinder, and used West Systems 403 filler to epoxy the core down to the bottom layer. We tried to grind a groove into outer edge to make sure when we were done with the project, the water still drained well to the corners.
After the core was bonded and ground out, we glassed it in with 1708 Biaxial fiberglass, which is basically a three-in-one fiberglass material for additional strength.
After the first fairing with West System 410 Fairing filler, we had to add an additional layer of fiberglass mat to build up the area to make it level. After each layer of fairing, we sand smooth and find low spots and imperfections. Expect 2-3 fairing layers to get the finish you want.
After the third layer of fairing, we sanded heavily. While it doesn’t look smooth visually, your hand is a much better gauge.
Once happy with the fairing, we reinstalled the steering pedestal to get the boat ready to go in the water.
We primed the repaired area with Total Boat Topside Primer, then finished with Total Boat Wet Edge Topside Paint. We used a foam roller with moderate success (it disintegrated pretty quickly)
To be continued… we are getting Seadek in our cockpit! This is a picture of the templates we made and sent back to Seadek to be scanned. The process overall was very smooth, which we’ll show in a future post!
Hope you learned something, let us know if you’ve ever done core work on your boat. If so, how did you do it differently, and have any advice for us in the future? Let us know in the comments below!
