Rebuilding edge of plywood deck.

[ihrig]

Hello!

1958 25ft Cheoy Lee, folkboat copy.

Problem:

1) Replacing section of tek cap rail and rub rail.
2) Edge of underlying plywood deck rotten.
3) Varnished teak sheer plank split from cap rail being ripped out.

Ok, so I removed the luan rail installed by the Mexican carpenter. Saw soft wet ply underneath.
The plys are quite thick 1/8 inch.

My plan of attack is:

1) Run circular saw along strait edge to cut outside edge of ply deck.
2) Remove copper nails and roves from sheer plank.
3) Epoxy split plank.
4) Re-rivet plank.
5) Scarf and epoxy in ply deck patch. Using staples to be removed.
6) glass over deck patch.
7) 5 min epoxy stubs to deck.
6) Use wedges, stubs, and clamps to bend epoxy cap rail in place.
7) 5200 rub rail in place.
8) Remove stubs with heat gun or chisel.

Is this a good way to go? Any recommendations on
the type of plywood? Thanks!

Karl

[ 08-04-2003, 06:52 PM: Message edited by: ihrig ]

[Steve Lansdowne]

I doubt you'll get any replies to this message that are helpful. How about more details and/or pictures?

[Bruce Hooke]

In theory a bad section of plywood can be replaced with a new piece of plywood scarfed onto the existing good plywood. IIRC, the usual slope for a scarf joint in plywood is 12:1, so a scarf joint in 1/4" plywood would be 3 inches wide. Or, instead of a scarf joint you could back up a butt joint in the plywood with another piece of plywood.

However, something tells me that there is more to this issue than just cutting out the bad plywood and scarfing in a new piece...so, as Steve said, can you fill us in with more details?

[ihrig]

I sent an incomplete post. So I have added more details. Thanks.

[ 08-04-2003, 07:34 PM: Message edited by: ihrig ]

[Dave Fleming]

Where is the boat? I am in Pt.Loma perhaps I can look over your situation. Some folks in SD and in the Forums seem to think I know what I am talking about....sometimes.


<insert big wink grin here>

[ihrig]

The boat is in Ensenada, Mexico.

http://homepage.mac.com/karl_ihrig/PhotoAlbum2.html

[Mrleft8]

Ensenada? I could be convinced to go take a look in....November.....Through ........May..... ;)

[Dave Fleming]

The boat is in Ensenada, Mexico.Whups sorry, don't do Mexico.

[ihrig]

This scarfing of plywood is interesting. If the patch has perpendicular ply orientation at the scarf surface, then 12:1 scarf slope would make sense.
However if the faces have the same grain orientation, the slope only makes sense for the end-grain interfaces. However, end-grain absorbs more epoxy, and epoxy is stronger than wood.

With the type of loads on the deck, the framing, and glassing over, I bet a 4:1 scarf would work too. What the heck, I can afford 3-6" of plywood.

Dave, I have heard that they have EPA officers on kayaks who hand out $400 tickets when someone does sanding on their boat in San Diego. The yard in San Diego wanted $810 to haul my boat for one weekend. In Ensenada it was $310 for 11 days. I don't do California.

[Dave Fleming]

Kohlercraft wanted what for a weekend?!?!
I agree stay in Mexico. I just don't go down there anymore.

[ihrig]

This scarfing of plywood is interesting. If the patch has perpendicular ply orientation at the scarf surface, then 12:1 scarf slope would make sense.
However if the faces have the same grain orientation, the slope only makes sense for the end-grain interfaces. However, end-grain absorbs more epoxy, and epoxy is stronger than wood.

With the type of loads on the deck, the framing, and glassing over, I bet a 4:1 scarf would work too. What the heck, I can afford 3-6" of plywood.

Dave, I have heard that they have EPA officers on kayaks who hand out $400 tickets when someone does sanding on their boat in San Diego. The yard in San Diego wanted $810 to haul my boat for one weekend. In Ensenada it was $310 for 11 days. I don't do California.

[ihrig]

Yup, that is what they wanted 6 years ago. My last haulout at Baja Naval was 11 days, included 24 hours of carpentry and consumables, all for the same price Kholer wanted for a weekend. Plus I have been able to use TBT, though now I can't buy it.