Soft deck repair 06 SX230

[Brad_Ct]

I know other people have had this done but I figured I would show the process that I used.

First I cut out the panel over the fuel tank with a saber saw on the sides and front and multi tool along the back, you need to be very careful not to go to deep along the back because of the fuel lines.

I then peeled the fiberglass off the back side of the panel, as you can see there wasn’t much wood left.

I ground off all the old wood and adhesive from the panel.

Using the old glass as a template I cut a new piece of plywood.

I epoxied the new wood to the old deck cover with West System Six10.

Then glassed over the new wood and trimmed it to match the deck.

The wood around the perimeter was also rotted so I dug as much of it out as I could and cut new pieces of plywood to fill the void.

I cut 3” pieces of plywood, slid the new wood between the deck halves with epoxy and epoxied the 3” pieces to the bottom of the deck to support the repaired section.

I them epoxied the repaired piece back into the deck.

And here you have the finished repair

 

[Brad_Ct]

Materials used
4x8x1/2” marine plywood $140.00
3 tubes of Six10 epoxy $100.00
501 epoxy pigment $25.00
fiberglass resin and cloth $35.00
Total cost of $300.00

 

[Jim_in_Delaware]

I’m a bit surprised you would have soft deck in a boat of this age. Is it fairly common?

Nice job with the repair! ?. How much time did this project take?

Jim

 

[Scuba_ref]

I’m a bit surprised you would have soft deck in a boat of this age. Is it fairly common?

Nice job with the repair! ?. How much time did this project take?

Jim

It is very common. It is due to the table mount allowing water intrusion. When I had mine repaired I went with aluminum instead of wood.

 

[Brad_Ct]

I’m a bit surprised you would have soft deck in a boat of this age. Is it fairly common?

Nice job with the repair! ?. How much time did this project take?

Jim

Thanks, it probably only took 8 hrs. actual time but the epoxy takes 5-6 hrs. to cure so there is a lot of down time between steps.

 

[Scottintexas]

I’m a bit surprised you would have soft deck in a boat of this age. Is it fairly common?

Nice job with the repair! ?. How much time did this project take?

Jim

Yes, also the cleanout hatch will rot, water gets through the latch seal