Bow deck repair

[littlebookworm]

I'm still working on my 1986 SunRunner 220SB, but things are coming along nicely. One problem I now have is a soft bow deck. My understanding is that the wooden core between the outer and inner fiberglass skins has rotted and needs to be replaced. I've read that the process involves removing the cabin headlining; cutting out the inner shell; removing the rotted core; cutting and gluing in a new sheet of plywood; replacing and glassing in the inner fiberglass shell; and finally, replacing the headlining. A couple of questions: How do you figure out how much to cut out in the inner fiberglass shell? I don't want to cut too large a piece, which would give me extra work to replace; and I don't want to cut out too small a piece, which would lead to piecing the inner shell. What kind of plywood is used for the repair? How is it glued/glassed in? What's the best way to reinstall/glass in the inner shell? Are there any guidebooks you can recommend? I'm not afraid of doing the job; I just don't want to screw it up. Thanks for any help; sorry about the long posting. Hy

 

[littlebookworm]

Re: Bow deck repair

As an added thought: Is there any product on the market which could be used as a liquid or foam, for example, that could be injected into the space between the inner and outer bow deck shells to strengthen and repair the rotted inner core? Assuming, of course, that I cut a series of holes through the inner shell and possibly vacuumed out the loose wood fibers. Any advice or info out there? Thanks in advance. Hy