1994 Catalina 36 MKII with Soft Spots in Deck

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Moonstruck
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1994 Catalina 36 MKII with Soft Spots in Deck

Hello all,

I had posted previously that we were looking at a '95, but that one just had too many issued to consider buying.  We've now found a '94 that is in much better condition overall, EXCEPT...

There are noticeable soft spots in the deck around the chainplates.  They also sound hollow when we tap the deck with the handle of a screwdriver.  In total, I estimate that the voids are 12" x 24" on each side.  I would prefer to repair these from below, as I am concerned about achieving an undetectable repair if we do it from above.  It appears to me that we can get to the bottom of the deck, cut out a couple areas to pull out the rotted core, reinstall the fiberglass that was cut out, and then fill with thickened epoxy. 

First question:  Will this work?  Has anyone here ever done that? 

Second question:  What would be the expected cost for this repair if we had it done by a professional?

Third question:  Can anyone here recommend a professional in the Tampa area to do this?  Normally I would not hesitate to take this on myself (I am a bit of a perfectionist), but my new job ties up so much of my time I think I'll have to get someone to do the work.

Thanks!

Bruce

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Catboat Willy
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Joined: 12/22/14
Posts: 387

Bruce; Check your personal messages here on the forum.
Bill

Bill Dolan 1990 Catalina C-36 MKI - Hull #1041  'Williwaw'
Std. Rig, Walk Through, Wing Keel
M35, Oberdorfer Conversion,
Home Waters; Charlotte  Harbor & The Gulf Islands of Florida
'You are never out of work if you own a boat'

 

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LeslieTroyer
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Posts: 533

Everything I've read really discourages repairing from below.   You can either purchase or make non-skid molds to match you existing deck - I've got a few spots to fix on my 1983 MK1 - I was going to get things close and  repaint with KIWI-Grip

good luck

Les & Trish Troyer
Mahalo 
Everett, WA
1983 C-36 Hull #0094
C-36 MK 1 Technical Editor. 

Commodore

 

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bcam
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Joined: 6/29/07
Posts: 77

We had the same problem on our '95. We first tried drying the decks out by drilling holes in the overhead and using a strong dehumidifier, No good.

The solution was to remove 8' of deck on each side, replace the soaked plywood with closed cell foam and build new decks. The final cost was over 12,000, but we felt it was worth it for our peace of mind. 

I can send pictures of the work in progress, if you would like.

Bruce

Bruce Campbell
Evergreen Dreams #1409

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