One of the things I knew we had to tackle this winter was the anchor locker lid. During the purchase survey it was noted that it had significant water in the core, and this was after the boat had been on the hard and covered. After one season with the boat, it was now so wet we couldn't stand on it without feeling like we would fall through. I think it was telling that when in November we had below freezing temps for a week, the cover had actually gotten rigid again, I think because the core had froze (the surface was lumpy, and as you can see in one of the first pictures, I think it actually split the back joint of the cover). Through this split you could clearly see a very very soggy core, yes that is mold .
I built a wood frame with several stations scribed from the deck and cover in place so the cover would maintain the correct curvature during repair once I tool the inner skin off.
Then went about removing the bottom skin and core. I found the best method was to cut the skin with a angle grinder and a cutting wheel, later cutting it into 1" wide strips and then prying with the chisel. The corners I did with a Dremel equipped with a 561 multipurpose bit. So after much chiseling and cutting, I now have a bare single skin. Some things to note, maybe about 20% or so of the original core was dry, and came out hard, as can be seen where you see the white of fiberglass instead of the brown of wood in the final picture. Also, I had thought water was coming in from the hinge bolts, but now I can confirm they were never through anything but solid glass, the handle bolts however, clearly were through core, and I think this is where most of the water came from. It looks like it traveled across the back of the cover, and then wicked up the two sides and down the centerline of the cover. I think because it is on a incline from aft to fwd that is why the fwd end was in better condition. I don't know why, but Ericson brought the core very very close to everything.
It should be noted I have ZERO experience with fiberglass, so this is my first foray into the repair world. I am sure I will get them here, but any tips or help is appreciated, otherwise I'm just kinda making it up as I go, and reading others posts like kiwisailor's.
How I am planning on doing things:
1. Prep the inside surface, just sand with 80 grit??
2. Maybe putting down a thin layer of pure resin to seal all of the loose fibers that I disturbed when removing the core, and maybe to give the panel some more rigidity? Do this with a new layer of fiberglass?? I'm still divided on this.
3. Put a new core in. Set core into a layer of slightly thickened epoxy.
4. I am planning on filling all the corners with epoxy and the edges around the core. Epoxy blended with 406? I also think I should fill where the handle is, as the original pocket that kind of contours around the handle meant that the nuts on the bolts were not on a smooth surface. This caused them to bend when tightened. I think it would be better to give them a flat surface to bear on. Do this first then lay the bottom skin on at the end? I'm also of mind to make the hinge areas thicker, but I have to check clearance to the anchor locker flange.
5. Put a new skin on bottom.
6. Paint (not sure what product I will use yet).
Thanks for any and all input!
I built a wood frame with several stations scribed from the deck and cover in place so the cover would maintain the correct curvature during repair once I tool the inner skin off.
Then went about removing the bottom skin and core. I found the best method was to cut the skin with a angle grinder and a cutting wheel, later cutting it into 1" wide strips and then prying with the chisel. The corners I did with a Dremel equipped with a 561 multipurpose bit. So after much chiseling and cutting, I now have a bare single skin. Some things to note, maybe about 20% or so of the original core was dry, and came out hard, as can be seen where you see the white of fiberglass instead of the brown of wood in the final picture. Also, I had thought water was coming in from the hinge bolts, but now I can confirm they were never through anything but solid glass, the handle bolts however, clearly were through core, and I think this is where most of the water came from. It looks like it traveled across the back of the cover, and then wicked up the two sides and down the centerline of the cover. I think because it is on a incline from aft to fwd that is why the fwd end was in better condition. I don't know why, but Ericson brought the core very very close to everything.
It should be noted I have ZERO experience with fiberglass, so this is my first foray into the repair world. I am sure I will get them here, but any tips or help is appreciated, otherwise I'm just kinda making it up as I go, and reading others posts like kiwisailor's.
How I am planning on doing things:
1. Prep the inside surface, just sand with 80 grit??
2. Maybe putting down a thin layer of pure resin to seal all of the loose fibers that I disturbed when removing the core, and maybe to give the panel some more rigidity? Do this with a new layer of fiberglass?? I'm still divided on this.
3. Put a new core in. Set core into a layer of slightly thickened epoxy.
4. I am planning on filling all the corners with epoxy and the edges around the core. Epoxy blended with 406? I also think I should fill where the handle is, as the original pocket that kind of contours around the handle meant that the nuts on the bolts were not on a smooth surface. This caused them to bend when tightened. I think it would be better to give them a flat surface to bear on. Do this first then lay the bottom skin on at the end? I'm also of mind to make the hinge areas thicker, but I have to check clearance to the anchor locker flange.
5. Put a new skin on bottom.
6. Paint (not sure what product I will use yet).
Thanks for any and all input!