I will try to make this short and sweet. I bought a 1991 Four Winns Horizon 200 last year. On the maiden voyage I discovered a "medium sized" leak in the transom. Removed engine, replaced transom seal on the Cobra I/O. Performed minor tune up and re-gasket of Cobra 5.8l (351 Windsor), rebuilt starter, replaced ring gear on flywheel. Inspected transom wood, all solid and good. After 200 miles on the lake, no leaks, but soft spots in the floor. One spot of the floor aft of the bow area ceased to exist after that trip. I parked it for the winter and vowed to replace the deck in the spring. Its now late spring and a 2 week lake trip is on the calender and I am demo'ing the floor. "If you cant do things at the last minute dont do em". Four Winns decked this boat with 1/2" ply and did a great job of glassing it out to within 1" of the ski locker and fuel tank hole. Must have been a Friday at the factory and the "boys" left early. Stringers are solid and glassed beautifully, foam is dry, but foam under glass benieth locker and fuel tank is soaked. The "boys" also left before glassing the hole in the bulkheads. The deck is rotten back about 4" from the edge of the bulkheads. I have 5 weeks to make this boat pass the Admiral's(wife) inspection so here is my plan/question for all you seasoned boat monkeys out there. I cant find marine ply in 1/2" so I am planning on using 1/2" Auraco. Ply. Saturating with poly resin on all sides and edges with 1 layer of 1.5OZ CSM before laying down. Then 1 layer CSM, 1 of woven Mat to tie it in with the side of the hull. Under the locker and the fuel tank I plan on drilling 2" holes, removing all wet foam and replacing. Glassing entire Keel area bow to stern and building new bulkheads and fuel tank mounting wich will also be glassed. My Question is; is Auraco ply good? If not What else can I use? What adhesive to use between deck and stringers and will stainless wood screws through adhesive with glass on top last? Thanks in advance for any input you can give. Im an ex grease monkey that aint afraid of anything. Except the admiral's fury. If she's happy, then everybody's happy.
