Re: 1961 Larson All-American 14'
6 months ago when I split my deck I used epoxy in the little seam to epoxy it back together. I should have glassed the underside at that time, but I was in a hurry to get the boat back on the water. Last weekend I noticed a small crack where I had joined the deck seam. By the time I was finished boarding, I knew I needed to fix it correctly.
The above photo shows the deck after I took the grinder to it to remove a lot of the orginal glass so I could add an epoxy fillet. These old Larsons used a lot of glass in the deck!
The above photo shows thickened epoxy applied the area I ground. You can see a small clamp holding the deck lined up while the epoxy sets. I let this epoxy dry for 24 hours before doing anymore work.
The above photo shows me fairing the repair. I used polyester resin (bondo) over the epoxy because it dries faster, and it's so much easier to sand than epoxy. I love the strength of epoxy, but I hate sanding that stuff.
The above photo shows the area being masked off for paint.
The above photo shows the completed repair. I'm very happy with the results. Black shows every little imperfection. I cannot tell where the repair was made, and that's looking at it from different angles - not just straight on.
I sanded the epoxy with 80 grit. I sanded the polyester resin with 100 grit, and finished everything with 220 before applying the paint.
I also used 6 layers of 4oz. fiberglass tape on the underside of the repair. I imagine it's just as strong, or stronger than the original deck now.