On Thu, 06 Nov 2008 07:59:46 GMT, Jere Lull wrote:

On 2008-11-06 00:06:59 -0500, Wayne.B said:

Method 1 is scary but probably yields the best long term out come.
Some people have reported success making a thin cut around the
perimeter of the repair using something like a Fein Multimaster to
make the cut; lifting off the outer skin intact; and then replacing it
at the end, leaving only the cut line to be patched up cosmetically.
One difficulty is predetermining the extent of the core damage.

I did this with Xan's port deck a dozen years ago. Still haven't gotten
to the starboard side. It was really a fairly easy job with our big
flat deck. Might have taken 3 weekends to do the bulk of the work, and
most of that was thinking or waiting.

Surveyor said the delamination wasn't a problem if we didn't see stress
cracks. Still none, so I put up with a bit of spring in my step on that
side.

Tip: A real nice way to chip core out of the corners is to fit router
bits to a 6-12" drill extension with a ball bearing collar between the
bits and extender. Lets you rest against the surface you want to NOT
chip yet get pretty deep -- pretty much the length of the whole
assembly.

There is a chapter in the Casey (Sp ?) book about removing the outer
skin in one piece and replacing it.

I attempted to do this on a side deck next to the cockpit. Problem...
Boat built with inch dimension plywood core and only metric available
here. But other then that it would have been a fairly simple process.

Do remember that the joint where skin cut was made needs to be ground
back on a taper and a full thickness tapped joint made here.

Bruce-in-Bangkok
(correct Address is bpaige125atgmaildotcom)