Frank Gerry wrote:
Has anyone seen this problem before. This fall, I attempted to repair
leaking deck though-holes. My Cal 28 uses U shaped bolts for the anchors to
the mast stays (instead of chainplates).
The deck through-holes were 3/8 inch diameter, so I drilled thru the deck
with twice the size diameter holes (3/4 inch). I then taped underneath and
filled in the holes with fiberglass resin. A week later, I inspected the
glassed in holes and discovered some were leaking as badly as before.
The mistakes I made I think were 1) the inside of through-holes were still
wet when I poured the resin, and 2) I used polyester resin and not epoxy
resin.
Anyone have any suggestions what I could do before I head out and re-drill
these.

Frank



How wet might the deck have been? Is it cored? If so, what
material for the core? Did you scrape out the coring inside the
deck about a half inch? Was the removed coring sodden and black or
what?

For this amount of work, epoxy would be cost effective, but, see
below, as to wether even it could work.

Is there any chance the leak is caused by relative motion between
the hull anchors for the u bolts and the deck, flexing with foot
pressure or hull flexion, or thermally induced expansion and
contraction? Perhaps you need a resilient permanent sealer, like
5200? I have heard that it is better to use slack fit top and bottom
plates, through bolted, with the spaces filled up with a flexible
polyeurothane bedding material, or polysulfide.

You might not ever get a solid seal to work there for long if you
sail hard without knees under the deck.

My chain plates are bolted through the side of the hull, and do not
pass through the deck. Any chance to modify your rig, and use real
"Chain Plates?" Or, are your shrouds inboard?

Terry K