1996 Grady Islander Stringer rot repair

[greauxpete]

While poking around in the bilge we discovered the starboard side stringers were not capped with glass from the factory and had turned to mush. After some deliberation, we decided to cut the inside glass skin out and will be replacing with new epoxy coated plywood and covering the new plywood with 3 layers of 1708 and west epoxy.

See below:

Inner glass cut at blue line about 1" above floor.



Inner glass removed, rotted plywood removed, gel coat on floor ground out a distance of 4-6" adjacent to stringer:

 

[seasick]

This video shows the recommended method for glassing plywood to a flat surface. The ere different ways to get a good result but the practice of using a fillet to add some radius to the 90 degree joint adds a lot of strength and crack resistance

 

[Fishtales]

I hope someone at GW monitors this site. It's an older hull but the workmanship just isn't there. They need to start addressing the weak points of their designs - especially things that observed for many of the boat models.

 

[greauxpete]

Yes, disappointing lack of quality control. The starboard side stringers are not capped with glass cloth, only gelcoat. The gelcoat wasn't thick either as the end grain is visible. So the strength is lacking as you have an open shape versus a closed shape. We're going to fix that. Additionally, the glass on the starboard side isn't very thick, perhaps by design but other areas look thicker.

Fortunately, we hit good wood at the forward tank bulkhead, but we removed it all.

Seasick, thanks for the link. That's exactly what we intend to do.

 

[greauxpete]

Progress:

Ground out old stringers and gelcoat.
Test fit new stringer.

 

[Hookup1]

Did you remove the top half of the boat back there for access? A photo would be great. I have a 1997 Islander and someday I may be back there!

 

[greauxpete]

Hook-up, no the cap is still on, but we removed the rear hatch. We're doing boat yoga to get in there. It's a rough job. I'll get some pics next time I'm there. BTW, that's 1/2" marine plywood. Seems to fit about right.

Could you take a picture of your stringers under the battery shelf on the starboard side? My stringers were not wrapped with glass over the top of the plywood and I believe this contributed to the rot, as the end grain was exposed and delaminated. If you're stringer ends are exposed and still good, I wood wrap them with glass to prevent moisture from entering.

 

[family affair]

Did you remove the top half of the boat back there for access? A photo would be great. I have a 1997 Islander and someday I may be back there!

The good news is that your transom should be greenboard. The bad news is your stringers might not be. Word is 97 was a transition year to all greenboard transoms. It is not clear if all boats got greenboard for stringers. If your boat was a 98, you'd be in the clear.
Nice work Pete. I can't imagine how much it would suck to have to cut and grind back there. I'd saw the worst is behind you.

 

[greauxpete]

Thanks fam.. yes I figure we're about 50% in with the grunt work behind us.
Will keep everyone posted.

We're also making some minor repairs to the rear stringers on the same side which are not wrapped in glass on the top of the stringer. Trying to mitigate further moisture if at all possible.

 

[Hookup1]

Hook-up, no the cap is still on, but we removed the rear hatch. We're doing boat yoga to get in there. It's a rough job. I'll get some pics next time I'm there. BTW, that's 1/2" marine plywood. Seems to fit about right.

Could you take a picture of your stringers under the battery shelf on the starboard side? My stringers were not wrapped with glass over the top of the plywood and I believe this contributed to the rot, as the end grain was exposed and delaminated. If you're stringer ends are exposed and still good, I wood wrap them with glass to prevent moisture from entering.

Not easy to get in there but I'll try to get pictures.

 

[Fishtales]

Looks like a very nice fit.

 

[greauxpete]

Fishtales, I mocked it up with cardboard, then cut out the plywood, but it had to be incrementally trimmed to fit (allow rotation of the thicker and stiffer plywood)

 

[greauxpete]

Glassed top of taller area of stringer and test fit and how we are accessing the stringer..

 

[Don Davis]

Awesome craftsmanship and patience to work in tight spaces

 

[greauxpete]

Stringer are glued down with thickened epoxy (rock solid already) and we repaired the center stringer which had delaminated glass:

 

[efx]

Boat yoga. Islanders are hard to work on. Only boat I ever worked on where I had to stand on my head with my feet in the air. Nice job with the stringer. The boats are good. Thanks for keeping her sea worthy.

 

[family affair]

Boat yoga. Islanders are hard to work on. Only boat I ever worked on where I had to stand on my head with my feet in the air. Nice job with the stringer. The boats are good. Thanks for keeping her sea worthy.

Unfortunately 100% of what you said also applies to the 2003-2005's. I tolerate it because I love trailering to change the scenery. No regrets.

 

[greauxpete]

We laid up 3 layers of 1708 tonight:
Total thickness = 0.044" * 3 layers = 0.132" thick

 

[Fishtales]

Looks great. Nice job....

 

[greauxpete]

Getting close: