Soft spot core repair

[Pat Hurley]

Finally repaired/replaced soft core area on cabin top, port side of bomar hatch. I was able to accomplish this without cutting the top skin by removing the bomar and excavating the soft balsa core. After removal and drying out process I fashioned some tools to sand both the undersides of the glass skins. I used white oak cut to fit ribs then coated those with West System epoxy and let those cure before removin blush and sanding to create a profile.

after sanding and dry out of the hollowed core area I wetted out the undersides and buttered in those pre prepped oak ribs using thickened epoxy and a modified extension tube to a caulk gun to inject epoxy back into the far reaches and stack the ribs in as I proceeded. In the end it turned out better then I expected and the cabin top is harder and more solid then a w€ddin d!€k.

 

[Pat Hurley]

The water intrusion was coming from a couple sources. One area was the foot of the pipe work hardtop support, the factory installed snaps for the seat cushions and at the bomar cutout. All fasteners etc now are sealed or screwed into epoxy and rebedded so this won’t happen again as long as I’m on the sunny side of the dirt.

 

[Fishtales]

Nice job Pat.

 

[Byram]

well done. What kind of tool did you use to excavate so deep between the layers.?

 

[Pat Hurley]

… thanks Dan

Byram, I fashioned a couple different pieces of 3/8 all thread rod. One with a pointed angle and another with a pointed hook. Using them to dig out the soft core while the threaded rod served as a file or rasp of sorts scraping and digging simultaneously. It worked fairly well removing 95 + percent and made fast work of the soft core. What little remained I sanded with 80 grit wrapped and stapled on a piece of 3/4” x 2 1/2” poplar fastened to a reciprocating tool.

 

[Byram]

Thanks Pat, Great idea on the sanding !! I have found a soft spot as well and will probably cut an area large enough to put in a hatch and proceed as you did.

 

[efx]

Excellent process. Granular.

 

[seasick]

Very creative solution.

 

[DennisG01]

Great way to do that, Pat!

 

[Meanwhile]

Thanks for posting these ideas. Makes a great site.