Wide Open Throttle
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- Feb 6, 2010
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I was originally set to remove and replace a flimsy floorboard. Once the board was removed, I realized further hidden damage to the stringers. I opted to go with the less evasive route and choose to surgically (sort of) cut out the rotted local sections and splice in fresh vertical cut doug fir.
I used the old cut out sections as a template to fab the replacement splices. There were four rotted sections in the two stringer configuration were the seats were bolted with lag bolts. After duplicating the replacement sections, I sanded and prepped each, using strips of mat glass and resin. I layed up the area using duct tape to act as a sealer along the vertical sides of the stringer not allowing the resin to leak out the sides, then applied top pressure by weighing it down with the battery.
Later sanded and routed the edges and fully glassed the repaired stringers. I pulled out all the old water saturated foam and added two more bulkheads for structural support in lieu of the foam. Shaped and sealed/glassed a new piece of marine ply. The new board is rock solid and expect this repair to last another 20 years (hopefully).
I used the old cut out sections as a template to fab the replacement splices. There were four rotted sections in the two stringer configuration were the seats were bolted with lag bolts. After duplicating the replacement sections, I sanded and prepped each, using strips of mat glass and resin. I layed up the area using duct tape to act as a sealer along the vertical sides of the stringer not allowing the resin to leak out the sides, then applied top pressure by weighing it down with the battery.
Later sanded and routed the edges and fully glassed the repaired stringers. I pulled out all the old water saturated foam and added two more bulkheads for structural support in lieu of the foam. Shaped and sealed/glassed a new piece of marine ply. The new board is rock solid and expect this repair to last another 20 years (hopefully).
Attachments
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1.jpg85.6 KB · Views: 676
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2 Old Floorboard.jpg75.8 KB · Views: 661
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3 Floorboard removed showing stringer rot!.jpg66.9 KB · Views: 682
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4 This Is Gonna Be A Big Job!.jpg73.2 KB · Views: 686
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5 Driver Side Stringer View Aft Pretty Bad...jpg47.6 KB · Views: 675
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6 I Need Repairs I Am Rotting Away!.jpg88.4 KB · Views: 671
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7 More Rotted Stringer Removed.jpg87.2 KB · Views: 658
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8 Sections of Rotted Stringer Removed.jpg82.1 KB · Views: 652
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9 Fiberglassed Stringer Repair.jpg81.7 KB · Views: 643
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10 Replacement Stringer Section.jpg87.1 KB · Views: 639