1st post, looking for advice

[earle]

Originally Posted by scook

One piece is definitely the easiest (as big a piece as you can get into the cabin) but you need to be sure the surface above is flat enough that the plywood will stick to the whole surface. Take a straight edge, a level, aluminum bar stock, etc., and check the surface for flatness so you know what you're dealing with.

When you dry fit the plywood, make some sticks the right length from scrap lumber to wedge in under it and have them handy when you goop it up to hold it firmly up against the overhead.

Thanks for the tip. Exactly what I was mulling over. I'm going to get 3 or 4 strait pieces of lumber, long enough to reach over the entire width of the top of the deck, and put a bit of weight on each end of them. Then when I fit the new piece underneath I can temporarily shim it using your suggested wedges. As long as the top strait edges remain flat on the deck, with no high/low spots, I should be okay.

[scook]

I'd brace it up so there's at least some hump in it - you don't want puddles on your deck.

[earle]

Originally Posted by scook

I'd brace it up so there's at least some hump in it - you don't want puddles on your deck.

I understand. I was thinking the same thing, but can't figure out how to do it, unless I glue the plywood up first and then glass the cross supports in place. Even then, will there be enough flex in the plywood to raise the centre line a bit after it's glued to the top?

[smokeonthewater]

Brace it up so it fits the shape of the deck exactly... Do not allow it to dry while bowed more than it should be...

If the deck is flat, so should the plywood be...

Cut the cross braces so that they exactly match the profile of the deck... Screw the deck piece to them and check that the profile has not changed.... Glass the assembly...

Then install in the boat with 3/16" peanut butter troweled on just like you would a floor tile....

Pre cut bamboo poles a few inches over length can then be bowed into place to firmly support it from the bottom and you can add weight from above if needed.

You can test the bottom support and weight system before gluing it together to make sure it's gonna work out.

You can also drill several 3/4" holes in the repair panel on say 18" centers to allow for both relief of the epoxy peanut butter and to manually verify that the panel is flush with the glass above it.

[earle]

Originally Posted by smokeonthewater

Brace it up so it fits the shape of the deck exactly... Do not allow it to dry while bowed more than it should be...

If the deck is flat, so should the plywood be...

Cut the cross braces so that they exactly match the profile of the deck... Screw the deck piece to them and check that the profile has not changed.... Glass the assembly...

Then install in the boat with 3/16" peanut butter troweled on just like you would a floor tile....

Pre cut bamboo poles a few inches over length can then be bowed into place to firmly support it from the bottom and you can add weight from above if needed.

You can test the bottom support and weight system before gluing it together to make sure it's gonna work out.

You can also drill several 3/4" holes in the repair panel on say 18" centers to allow for both relief of the epoxy peanut butter and to manually verify that the panel is flush with the glass above it.

Thank you. Just what I needed to hear. Man, this forum is so cool.

[smokeonthewater]

I've put a bit of thought into this lately since I'm gonna have to do it soon.... Damn cool of you to come along and test all this out for me :-P

[earle]

Originally Posted by smokeonthewater

I've put a bit of thought into this lately since I'm gonna have to do it soon.... Damn cool of you to come along and test all this out for me :-P

Happy to oblige. Appreciate the advice, just hope I don't have to report back on the resin in the armpit thing.