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Old 21-01-2012, 13:31   #16
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Re: Epoxy or Polyester Question

I do not know how old the boat is but you should find out if the deck is balsa cored. If so, it is very likely that water intrusion has created rot in the wood core. If that is the case, you will want to go ahead and cut away the decking from the top as far back as needed to eliminate the rotted areas. Then replace the balsa with klegecell foam and glass back over it with epoxy. you may use various fillers for the different conditions and engineering needs. Scarf the edges and fair out the repair.

Now the real work begins...refinishing the entire deck.
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Old 21-01-2012, 18:53   #17
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Re: Epoxy or Polyester Question

Be aware that epoxy will exotherm out of control if too large a volume is mixed and used on one place. If it is spread thin it can dissipate the heat generated by the reaction. If you are filling a volume 1" thick by 2-3" dia. you run the risk of too much heat. I would do a test pour first in a movable container of similar proportions to your repair. If it starts to run away drop it in a bucket of water and then you'll know you need to fill your repair in stages.
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