Re: Soft Deck
RagHauler,<br /><br />You could cut the top layer of glass off leaving about a 3-4" permiter in your 6 sq. ft. area. Then remove the rotted plywood. This would leave the bottom layer of glass in tact. Use a circular saw with the blade set deep enought to cut the top layer of glass and the plywood core, leaving the bottom layer.<br /><br />Remove all rotted wood. Replace the wood with doug fir (correct thickness, 1/2" or 3/4 or whatever you have or layers of 1/4" with a layer of glass between each). Fill gaps with around the edges (before you put the wood back) with high density adheasive filler (West systems has a product that does this when mixed with epoxy). Also put a layer of glass on top of the bottom layer, making sure it is well sanded and clean. Then glass over the top surface and finish.<br /><br />This is the same technique you would use on a transom repair, where 1 layer of the glass is kept in tact. If you are talking about a 6 sq. ft. that is accessable you should be able to get the old stuff cut out and the new stuff all glassed in in an afternoon, let set overnight (at least) and then be ready for finishing.<br /><br />There are multiple non skid products available (pettit makes a pretty good additive to their products). I think you would be surprised with the proper amount of sanding and prep how easy this can be to get a really good finish. You can also extend the repair to whatever "lines" you want. If the area extends to any angle or corner once the finishing is done the patch will not be as noticable or not at all.<br /><br />Parts List:<br />2 qts epoxy<br />4x8 plywood sheet(s) (depends on the shape and size)<br />High Density filler<br />Disposable rollers and brushes (2 ea.)<br />1.5oz Glass 6 sq. Ft.<br />Finishing material (Gelcoat, paint, primer, etc.)<br /><br />I think I forgot something, but you get the idea.<br /><br />In my oppinion, any repair you try to make to the core without getting all the wet wood out is going to come back to haunt you. There is a product called "Git rot", it is a very thin substance that you would use similar to the method of dilling holes. If you drill the holes at a steep angle you may be able to make the repair from the underside, but I would recommend against it.<br /><br />Hope this helps.<br /><br />Safe boating to all.<br /><br />Cheers.<br /><br />emp.
