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This is a surprisingly quick part of the
process – using an oscillating multitool
saw blade Andy was done in less than half
an hour, having started by roughly
marking out the outline of each cut out.
This offers more control, less chance of
personal injury and a lot less dust than
using a cutting disk in an angle grinder,
even if it takes a little longer.
The cut out needs to be an inch or two
smaller than the foam panel – the new
foam can be tucked underneath and this
approach staggers the joins in the
different materials. Typically on a boat of
this age that’s constructed from chopped
strand mat, you can expect the top
laminate layer to be 3-5mm thick and the
foam below it 10-15mm. Newer boats that
incorporate woven rovings or use vacuum
infusion moulding techniques will have
thinner laminates.
If it’s not easy to see where each piece
of core material is on a more conventional
deck construction, remove the headlinings
so you can see the laminate on the inside.
Then drill a pilot hole right through the
deck an inch or two in from each corner.
You can then join the dots to see exactly
where to cut. Tape over the holes on the
inside so that resin isn’t extruded through
them when you come to relaminating.
Once the laminate has been cut
through all round it can be levered off the
foam and the lower skin of the deck. If
there’s extensive delamination this should
be an easy process, but if not then use
wedges all round to gently ease it away
from the underlying substrate – you don’t
want to risk breaking the top layer.
You’ll probably find a lot of it comes away
easily – much of La Rochelle’s was badly
crumbling – but some will still be well
adhered. If so a 2in (50mm) chisel should
make quick work of separating it from the
laminate. A narrower chisel will help you
clean out the recesses around the edges.
Don’t forget to clean the underside of the
top layer of laminate so it’s ready to be
replaced later on.
(^1)
Marking out the areas of top
laminate that are to be cut away.
4
It may still be stuck in places, so
take care when removing it.
5
With the
upper skin
of laminate
removed the state
of the foam core
becomes obvious.
7
Pay attention to the edges, scraping
back underneath the laminate.^8
Sweep and vacuum the foam dust
and crumbs so the area is clean.
6
Use a broad chisel to scrape the
foam off the lower laminate.
(^2)
Cutting the top laminate is relatively
easy using an oscillating multitool.
(^3)
Once cut all the way around, the top
laminate can be lifted off.
REPAIR CORED DECKS
Removing the top layer of laminate
Scraping out the old core material
Step
by
step