I've replaced about 15 square feet of my balsa core at sections averaging 2 to 3 square feet at a time. I replace my original balsa core with end grain balsa tiles that I place slightly apart so that there is a distinct epoxy
dam between each so that no water
intrusion or decomposition may traverse these areas in the future and I can still retain the light weight.
I cut off the top deck plate with a grinding wheel
anf remove all the remnants of decomposed material making up the inner laminate. Then I spread a thin laer of epoxy on the dried bottom layer to seat the array of new balsa tiles. I then grind down the tiles so that I have about a 1/16 inch gap between the top of the tiles and the bottom of the removed deck plate.
At this point I fill the gaps between the tiles with poured epoxy and begin laying fiberglass cloth saturated with resin on top of the tiles and followed by seating the top deck plate. I carefully measure the height of my work so the reinserting the formerly removed deck surface is flush.
After all is cured I take a grinding wheel
and taper the edge where the removed plate meets the undisturbed deck so that I have a wide shallow trough that I will span with layers of cloth and resin.
After faring my finished repair flush I I have been using an Interlux
one part epoxy paint
(Brightsides) with quartz sand sprinkled from a salt
shaker to blend with my existing non-skid.
are can not be distinguished from original sections of m deck.
Please note that this seam was fared out to a far wider area after this next photo!