Cuddy Deck Repair

[joe7670]

So my cuddy deck has a few soft spots. Especially around the forward cleat.

I'm thinking of cutting out the top layer of the cuddy deck (similar to the the floor repair process) stripping out the wood, glassing new wood in and then reattaching the deck sheet to make it look fishished. Maybe even some sandy white paint over it all.

Anyone done this around here? Anything I should be watching out for?

[macojoe]

The best way to do it, but harder is to remove the rub rail, and all screws, separate the cap from the hull, and take it off.
Remove the windshield and flip upside down, remove all the little squares that make up the core and replace all. Then reassemble. will last you for a life time and still look original

[Mikeyz]

I agree with Macojoe, It will be more work to pull the cap but a lot less fiberglass work. I just pulled mine off and was not that hard to do. ( see my post for pic's and how to ). Also can you get to the under side of the cuddy deck in the cabin? If you can maybe try and fix it on the boat without cutting the deck off. I just think it gonna be hard to make it look right. I am not a expert by no means but I would try and fix from the underside if you can..

Mike

[macojoe]

Going from under is going to suck!! everything is up side down, and you going to have a real hard time unless you are a pro glass guy to hold that up there with wet glass!!

[joe7670]

Aside from the seam which I will have on the top side which I can take care of is there anything that would keep me from doing this from the top?

[macojoe]

You can do anything you want, but you asked for Ideas and the way we have said is the best way

Good Luck

[joe7670]

Trying to stay away from lifting the cap off. I was hopping someone has tryied the way i'm thinking and may have some things to watch out for.

I'll see once I dig into it around Oct.

Did others think Skools was crazy when he cut out the floor without lifting the full cap? I'm gonna try it on the cuddy deck. I think it will work.

[macojoe]

Floor is easy, just cut out the area and redo, you don't need to be up side down or anything, that's comparing Apples to Oranges

[joe7670]

Sorry, not understanding me. Or maybe i'm the one thats lost.

Most likely the later.

I'm expecting to remove (from the top) the top layer and the wood squares. Cutting at the red line in my oh so great MS Paint file.
Leaving the bottom layer of glass in place. Meaning don't cut through that bottom layer of glass.
Maybe it won't work if you think that bottom layer of glass it too thin to stay intact?

Then insert some 1/2" ply in the hole with some resin.
Finally put the top glass cap back on with resin and glass at the seam.

[garagenc]

If you go from the bottom, cut your wood blocks (replacements) small enough you can hold them up with duck tape. Then you can glass to your hearts content. I did that to a soft spot in my deck back aft near the floor drain. Tapeing them in place worked like a charm and I didn't have any problem with the glass not stcking to the wood.

There are other things you can use to hold the wood blocks up, liquid nail would work.

[phatdaddy]

does your cabin still have the llama skin intact? not really sure if there is a layer of glass on the bottom, just resin soaked wood. you also have the framing for the sliding hatch. i think jj in PR had the same issue at one time and he just added additinal bracing underneath.

[macojoe]

That might work well??

But you will have to make sure you get the the ply to bend to the shape of the deck, and filled the right way so there is no pockets under the finished top.
From doing from under you avoid all them issues as any imperfections will be under and never seen.

You could also do from below and use some sheet rock screws from top to screw ply up, Then when finished remove screws from top and just need to fill the small screw holes

[joe7670]

Now there's a possible drawback. If the bottom is just resin soaked wood then my approach will defnitely not work.

Let me check into it and report soon enough.