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[Gabe Berkey]

Hello all,

I introduced myself back in February, then disappeared. Appalachian Trail backpacking trip and my first season post retirement as a charter captain kept me busy. Summer charter season was outstanding. Now it’s time to get ready for duck boat season.

I’ve started the re-core project on my BBSB. I know there’s a ton of experience on here. I don’t have any experience with this. So I’m seeing any/all advice. I know I need to grind the skin down to remove all the rot. I’ve started that. I figured I’d roll on a coat of epoxy to the bottom skin as I place the pieces of core in. Then roll a coat on top of the core to reattach the top. I’ll fill in the saw cuts and fastener holes with thixo, or something like that (thicken epoxy in a calk tube).

If anyone can recommend a source for 3/8 ply for the core, that would help.

What should I use to patch cracks and chips in the top skin? Some kind of putty?

Like I said, any/all advice is appreciated.

Thanks,
Gabe

 

[Eric Patterson]

Gabe

I'm trying to wrap my head around what I'm seeing. Is that plywood sandwiched between fiberglass skins? It almost looks like cork. Is there another layer of glass under the rotten material? Is the plywood 100% rotten? Is there any good wood left? What kind of shape is the bottom half of the boat? In cases like this I've seen the top and bottom halves separated and reworked separately before joining them together again. I'm wondering if you need to go that route to get full access to the underside of the deck for the substantial repair ahead of you. In the past I've always used World Panel Products as my marine ply supplier but I suspect you have sources for marine ply closer by.

 

[Matt Mahoney]

Gabe

I'm trying to wrap my head around what I'm seeing. Is that plywood sandwiched between fiberglass skins? It almost looks like cork. Is there another layer of glass under the rotten material? Is the plywood 100% rotten? Is there any good wood left? What kind of shape is the bottom half of the boat? In cases like this I've seen the top and bottom halves separated and reworked separately before joining them together again. I'm wondering if you need to go that route to get full access to the underside of the deck for the substantial repair ahead of you. In the past I've always used World Panel Products as my marine ply supplier but I suspect you have sources for marine ply closer by.

Could it be end-grain balsa? A lot of boat decks were cored with that stuff back in the '70s and '80s. It solved the "lighter is better" dilemma, but if water entered the core (and it will eventually) the balsa soaked it up like a sponge. Most modern cored decks/hulls are something light and synthetic like Divinycell. I would be concerned about the weight of a plywood core.

 

[Shawn_B]

Hey Gabe, South Jersey Lumberman’s in egg harbor. Good pricing and local to save on shipping costs.

 

[Gabe Berkey]

Hello all and thanks for the replies. Haven’t had much surplus time to post but the project has been moving along. Slower than I hoped, but getting done.

The boat was cored with end grain balsa sheet. Matt was 100% right. This stuff: https://www.fibreglast.com/product/...Z9LqNBlddNU8B5QuarfoqLoNq6mMv6CRoCgq8QAvD_BwE).

The bottom skin of the deck wasn’t in bad shape. I was able to get a few needed repairs done from up top. The bottom of the hull is in good shape. The plywood stringer system needed attention. Ground out the rot. Reinforced with cloth/epoxy. Added drains to the stringers while I was at it. Not pretty work but they are solid now and won’t be a catch basin for water to freeze in blocks under the removable floor.

Lots of sanding/grinding got things cleaned up in preparation for the new core. I painted each block of the new core with epoxy. Bedded the core in thickened epoxy and laminated the top skin back on with another layer of thickened epoxy.

Added a shelf to the bulkhead that was already under the bow area. Installed a bow eye for the trailer winch (not the plastic pad eye in the picture haha).

I’ve put on two coats of Parker “dead grass” and reinstalled all the deck hardware/snaps for new dodger and blanket to hide under.

Almost there. I’m really looking forward to getting back on the water. It’s a fun little boat.

Thanks for the advice. I’ll update again soon I hope.