The fucking boat is a pain in the ass, but that's okay: you fight with, and for, the things you love.
May 1, 2011: All I've accomplished to date is epoxying the balsa core. It took from March 26 until now to get it done. Up next: fiberglass. They say that's easy. We'll see.
Step 1: Cut and peal/chip away fiberglass skin from under the deck. Previously I drilled holes to see where wet core was located, hoping I could dry it out rather than replace it, which turned out not to be doable (brown, rotten core). Cutting with an oscillating saw (Sears) worked pretty well, but the fiberglass was tough! It took awhile.
Step 2: Scrape and chisel away wet core; difficult in tight place such as around the bulkhead and by the cabinet. Sand surfaces clean.
Step 3: grind edges of cut fiberglass to create a bevel. Only the grinder tool will do it. Sanding is useless.
Step 4: Make paper patterns for replacement areas, then cut balsa to fit. Time consuming! Especially around the chain plate areas above the bulkhead, where I had to sand down the 3/4 inch balsa to fit. Use paper patterns for plywood templates to hold up epoxied balsa core.
Step 5: Get dowels and other wood to prop up templates. Cut plastic to put between template and glued core.
Step 6: Mix West System epoxy (205 hardener, 406 silica filler, 105 resin); make thick, peanut butter or mayonnaise consistency; apply with notched spreader on both surfaces; place and hold up with wood bracing.