Wellcraft Classic 180 deck replacement

[DoGood]

I've started working on the deck replacement of my 1988 Wellcraft Classic 180. This site is very useful and I'm looking for additional input as I go along with this project. My deck had a couple soft spots in it so I knew that I needed to pull it up and replace it along with checking the condition of the stringers. I've already test drilled the transom and haven't found any soft spots.

Here is the deck with the carpet pulled up.


Untitled by patrickrohlich, on Flickr


Untitled by patrickrohlich, on Flickr

rough cut the deck and started to pull it up


Untitled by patrickrohlich, on Flickr


Untitled by patrickrohlich, on Flickr

the worst of the rot on the engine hatch. Main seats were also pretty bad.


Untitled by patrickrohlich, on Flickr

 

[DoGood]

Re: Wellcraft Classic 180 deck replacement

And this is where I am now. Still have more deck to cut out, hopefully it doesn't take all summer.


Untitled by patrickrohlich, on Flickr

carpet pulled from interior pieces, some of these are still in pretty good shape despite that they are just wood with no fiberglass or resin.


Untitled by patrickrohlich, on Flickr

 

[DoGood]

Re: Wellcraft Classic 180 deck replacement

Now for some questions. I realize that I will find the answers to these from researching and reading other posts on this site, just putting them here so that I can remember them, though feel free to answer them if you want. Also if it seems I am going about something wrong feel free to give your comments as well.

I plan to cover all new wooded pieces with polyester resin and fiberglass cloth. I will use ~1/2" exterior grade plywood. A rough estimate would be 275 sq.ft. of area to cover. I need to know:
1) how much and what kind of cloth I will need
2) How much and what type of resin I will need. I know there is layup resin and finishing resin, can I get away with just using one type.
I will also need enough resin to fillet the edges from the deck to hull for a smooth transition.
3) what do I need to thicken the resin to make "PB" and how much will I need

 

[Tthomp3]

Re: Wellcraft Classic 180 deck replacement

The floor plan of this boat looks exactly like my well craft 186. its an 89 model and I'm doing the same exact process right now. for my stringers I'm using 1.5oz csm and 1708 biaxial and for my deck I'm using 3 layers of 1.5oz cam on top, 1 layer on the bottom and 1708 for the tabbing. The pb will require 1/4in chopped strand to give it strength and cabosil to thicken it. I used polyester resin due to the quick cure time and its a lot cheaper. As for the amount i can't really speak for the total because i only bought what i would need to get started, but expect to use at least 5 gallons of resin. Woodonglass has some great threads on what type of fiberglass you should use on the deck and stringers. I highly recommend checking out the link in his signature.

 

[DoGood]

Re: Wellcraft Classic 180 deck replacement

Working on my list of materials for my deck replacement.

40 yards x 38" 1.5oz. CSM (one layer on the bottom of deck, two layers on the top)
20 yards x 38" 1708 biaxial (two layers on top of deck, will also use this for tabbing in 6" strips, hope to have some left over to cover and protect new seats)
5 gallon polyester resin
2.5 quart aerosil-cabosil
2 lb. tub 1/4" chopped strand
some mixing containers (may already have these)
stir sticks and/or power mixing blade
a few squeegees/spreaders
a few rollers

I already have safety equipment like respirator, glasses, etc.

1) Is there anything obvious that I am missing from this list?
2) Am I right that I need a wax additive for the final coat of fiberglass? And do I use this on the bottom of the deck also?

 

[Tthomp3]

Re: Wellcraft Classic 180 deck replacement

i don't think 5 gallons is going to cut it to pb and do all your glass work

 

[Woodonglass]

Re: Wellcraft Classic 180 deck replacement

I agree ^^^

Not sure why you're getting the 38" instead of the 50">

Here is a helpful table for cloth:
There are about 150 ounces per gallon by weight

• 1.5 OZ MAT = 1 gallon covers 4.2 square yds
• 1.5 ounce cloth ( cloth not chopped mat)….1 gallon wets out 40 square yards
• 2.5 ounce cloth….1 gallon wets out 25 square yards
• 4 ounce cloth……1 gallon wets out 15 square yards
• 6 ounce cloth……1 gallon wets out 10 square yards
• 10 ounce cloth…..1 gallon wets out 6.5 square yards
• 18 ounce woven roving …1 gallon wets out 4.5 square yards
• 24 ounce woven roving …1 gallon wets out 3.5 square yards.
• Biaxial mat 1708.………….. 1 gallon wets out 4 square yards

Please remember several things:
- these are estimates not hard and fast rules.
- You should precoat the wood with resin and it will soak it up. Pay attention to the edges and make sure there are no voids. If there are fill them before applying any mat.

For a Typical 16 foot Ski Boat doing Stringers, Transom and Deck,
I’d recommend ordering the following… It should get you close.

10 gallons of Laminating Resin (maybe 15)
15 yds of 1.5oz CSM (Chopped Strand Mat) (50")
10 yds of 1708 Biaxial Cloth (50")
5qts of Cabosil
4lbs of ?” chopped Milled Fibers
Fiberglass Roller
If you are going to Gelcoat the deck 2 gallons of unwaxed Gelcoat and some wax for the final coat.
You might want to get some glass bubbles if you want to make your own Fairing filler.

 

[93bayliner1800]

Re: Wellcraft Classic 180 deck replacement

I just ordered almost the exact same amount for my 18ft Bayliner. Except I went ahead with 15 gallons of resin and I bought all 1708 30yds X 50" I am using all 1708 instead of CSM.

 

[Tthomp3]

Re: Wellcraft Classic 180 deck replacement

Yeah wood is pretty spot on with his calculations. i ordered the same amount of everything except i got 30 yards of cam for some crazy reason. oh well I'm sure i can just find another project to use it on