How to Fill in the cutouts?

[kanada]

1978 Aristocraft 19.
The foam between the deck and hull is waterlogged. In aristocraft forums the makers recommend cutting out access holes in the recessed carpet areas indicated in red to remove the foam. That sounds like a great idea.....

How to cover them back up after all the foam is removed? I will need to pour 3lb foam into the cavity for structure again..... just epoxy the cutouts back in place and that will be strong enough?

thanks,
Tomas

 

[ondarvr]

Re: How to Fill in the cutouts?

Before you do any cutting read other threads here about "soaked" or "waterlogged foam", the problems normally extend further than just the foam.

 

[Woodonglass]

Re: How to Fill in the cutouts?

Welcome to the iBoats DRY DOCK!

Yep, what he ^^^^ said. I am pretty sure there is MORE foam in your boat than JUST in those two areas and it will ALL be waterlogged I Suspect!! Boat of that vintage seem to have that issue and when they do, substructure will rot IF it is wooden. You MIGHT luck out and have a Total Fiberglass superstructure so further investigation on the structure of your boat is warranted. But as said before I would NOT be cutting anything until a TOTAL plan of action was decided upon. This could and probably will be a MAJOR undertaking.

 

[kanada]

Re: How to Fill in the cutouts?

Calm down guys.

There are no wooden stringers under the deck, its all fiberglass.
There is a fabric hose connecting sky locker to the bilge, the fabric is rotted and the moment I vacuum up the water from there with shop vac it fill up from below since the bilge is dry.

Previous owner put in a sky pole in the middle of the boat. To secure it they made cutouts and holes in the front of the sky locker to bolt it in, those holes let the water into the area between hull and deck.

The boat is rock solid, just heavy

 

[Woodonglass]

Re: How to Fill in the cutouts?

If that is the case then here is a drawing I did on how to patch the deck after cutting out a portion.
Hope this Helps!!!
Glue and screw the cribbing to the existing deck. Sand and clean the surface first. I'd wash the sanded area with Acetone before gluing and I'd use epoxy for gluing. You should cover the patch and all exposed edges with resin and 1.5 oz Chopped Strand Mat. The top surface of the Major Patch should have an additional layer of 1708 Biaxial Cloth IMHO.

(click to enlarge the pic)

 

[ondarvr]

Re: How to Fill in the cutouts?

If you have all glass stringers and transom then you have less to worry about...not nothing. Frequently the soaked foam isn't limited to just that one area and some hollow glass stringers are filled with foam, which may also be waterlogged. So the stringers need to be cut apart to remove the foam, this normally involves needing more access to a much larger area under the deck and more holes, or removing the entire deck.

You can use either polyester or epoxy to glass in the sections cut out to access those compartments

 

[Yacht Dr.]

Re: How to Fill in the cutouts?

1978 Aristocraft 19.
The foam between the deck and hull is waterlogged.

Uncap the deck and repair as needed ( doing this Right ).

YD.

 

[kanada]

Re: How to Fill in the cutouts?

Easier said then done.
Removing the deck will not help much. Will have to get the inner liner out also.
And all the cavities are filled with 3lb poured foam for structure....
And looking under dash - inner liner is bonded to deck at the top and to hull at the bottom.

Probably easier just to cut her in half.

Recommended foam replacement procedure by the manufacturer is to cut access holes under carpet and under front seats if needed.

 

[ondarvr]

Re: How to Fill in the cutouts?

Liners do make it more difficult, so back to cutting holes. Cut them big and then just glass them back in place, its not too hard.

 

[kanada]

Re: How to Fill in the cutouts?

4 holes 2x4 feet can be cut in areas that will be concealed to hide my beautiful glass work after the repair.
Will start from the back and see how far forward the foam is wet.

Thanks for all your advise.
Bearding the Cruise ship tomorrow, so little boat will have to wait a little.