Repairing Soft Deck On Your Wellcraft: A Step-By-Step Guide

Repairing a soft spot in a boat deck can be a complex process that requires a range of tools and materials. The first step is to assess the extent of the damage by tapping the deck and listening for a dull thud, which indicates a weak area. It is important to act on soft spots as they indicate an underlying problem that will spread if ignored. Once the weak areas are located, the next step is to cut them out, using tools such as reciprocating saws and grinders. After that, the area needs to be prepared for repair by applying a dewaxing agent, grinding the surface, and waxing the perimeter. The repair process involves filling the hole with a combination of materials, such as fiberglass matting and cloth, gel coat resin, and epoxy resin. This process requires precision and a good understanding of the chemicals involved.

Locate soft spots by tapping and listening for a dull thud

To locate soft spots in your boat deck, you will need to tap the deck and listen for a dull thud. This method will help you identify the areas that need to be repaired. Here is a step-by-step guide to help you through the process:

Step 1: Tapping and Listening

Using a screwdriver or a similar tool, start tapping on the deck in different areas. Pay close attention to the sound it makes as you tap. A sharp, crisp sound is a good indication that the deck is solid in that area. However, if you hear a dull thud or hollow sound, it indicates a potential soft spot. Mark these areas with a grease pencil or a marker to identify them clearly.

Step 2: Defining the Perimeter

Once you have identified the soft spots, you need to define the perimeter of the repair area. This means determining the extent of the damage and deciding how much area you need to work on. Use your marking tool to outline the weak areas around the soft spot. This will give you a clear idea of the size and shape of the repair section.

Step 3: Understanding the Extent of Damage

It is crucial to understand that soft spots are often indicative of underlying issues. Water may have seeped into the deck, causing the core material to rot or delaminate. By tapping and listening carefully, you can identify the boundaries of the damage. Make sure to mark all the areas that sound weak or hollow.

Step 4: Prioritizing Repairs

If you have multiple soft spots, it is essential to prioritize your repairs. Address the areas that pose a more significant concern first. Larger soft spots or those located in critical areas of the deck should be given higher priority. You can number or categorize the marked spots to create a clear plan of action.

Step 5: Gathering Repair Materials

Before proceeding with the repairs, ensure that you have the necessary tools and materials. This may include items such as a drill, reciprocating saw, gel coat resin, hardener, epoxy resin, and common building studs. Having everything ready will make the repair process more efficient.

Step 6: Seeking Professional Advice

If you are unsure about the extent of the damage or the best course of action, consider seeking advice from a professional boat repair specialist. They can assess the condition of your boat deck and provide expert guidance on the repair process. It is always better to err on the side of caution when dealing with potential safety hazards.

Cut around the area and clean out the soggy core

To repair a soft spot in the deck of your boat, you'll first need to identify the extent of the affected area. This can be done by tapping the deck with a screwdriver and listening for a dull thud, which indicates a weak area. Once you've located the soft spot, use a grease pencil to mark the perimeter of the area that needs to be cut out. This will ensure that you remove all the weak areas and soft spots.

When cutting out the damaged area, it's important to use the right tools. You'll need a drill and a reciprocating saw. Start by using the drill to create a hole that's large enough for the tip of the reciprocating saw to fit into. Then, use the reciprocating saw to cut out the soft spot and weak areas. Be sure to wear the appropriate safety gear and work in a well-ventilated area when operating power tools.

After you've cut out the damaged area, it's time to clean out the soggy core. Use a hand grinder to grind away any remaining debris and create a smooth surface for the repair. It's important to be thorough during this step to ensure a strong bond between the new core material and the existing deck. Once the area is clean and smooth, you can move on to the next step of the repair process.

At this stage, it's crucial to ensure that the exposed areas of the deck are protected from the elements. One way to do this is by creating a small dam system around the repair area using wooden battens, silicone, and modelling clay. This will prevent water from entering the exposed areas and causing further damage. Additionally, it's important to work quickly and cover the exposed areas with plastic and a tarp to protect them from rain or standing water.

By following these steps, you'll be well on your way to repairing the soft spot in your boat's deck. Remember to take your time, work safely, and seek additional resources if needed. Soft spot repairs can be challenging, but with the right tools, knowledge, and patience, you can restore your boat's deck to its original condition.

Sand and clean the inner surface

Sanding and cleaning the inner surface of your Wellcraft boat's soft deck is a crucial step in the repair process. Here's a detailed guide on how to do it effectively:

Prepare the Work Area: Before you begin, ensure you have gathered all the necessary tools and materials, including a respirator, safety goggles, gloves, a shop vacuum, an orbital sander, and sandpaper of various grits. It is also recommended to work in a well-ventilated area or wear a respirator to protect yourself from dust and fumes.

Remove Debris: Start by using a shop vacuum to remove any debris, dirt, or loose particles from the inner surface of the deck. This step is important to ensure that the sanding process is effective and does not push debris further into the surface.

Choose the Right Sandpaper: Select the appropriate sandpaper grit for the job. For most applications, 80- to 100-grit sandpaper is ideal for sanding away old paint or creating a smooth surface. However, you may need a finer grit, such as 120-grit, if the surface requires a lighter touch.

Begin Sanding: Attach the sandpaper to your orbital sander and start sanding the inner surface of the deck. Work in a systematic pattern to ensure you cover the entire area evenly. Apply moderate pressure and allow the sander to do the work. Avoid over-sanding any single area, as this can create dips or grooves in the surface.

Pay Attention to Detail: Be cautious around corners, edges, and contours. Use smaller sanders or hand-sanding techniques for intricate areas to avoid damaging the surrounding surfaces. If the soft spot is located near a non-skid surface, be especially careful not to create a slippery spot by removing the non-skid texture.

Vacuum Regularly: As you sand, periodically vacuum the area to remove sanding dust. This will help you monitor your progress and ensure that the sanding is effective. It also reduces the risk of the dust settling into other parts of the boat.

Clean the Surface: Once you have finished sanding, use a damp cloth or a specialized marine surface cleaner to wipe down the inner surface. This step will remove any remaining dust, debris, or residue left over from the sanding process. Ensure the surface is completely dry before proceeding to the next step in the repair process.

Remember to take your time and work systematically when sanding and cleaning the inner surface of your Wellcraft boat's soft deck. This process is crucial in ensuring a solid foundation for the subsequent repair steps, so don't rush it. Always prioritize your safety and wear the appropriate protective gear when working with power tools and chemicals.

Dry fit new core and wet with resin

To repair a soft spot on your boat deck, you will need to dry fit a new core and wet it with resin. Here is a detailed, step-by-step guide to help you through the process:

Dry Fit New Core:

• After locating and marking the soft spots, use a drill to create a hole and insert a reciprocating saw to cut out the soft spot. Ensure you cut through the top skin of the deck.
• Clean out the damaged core material, sanding and cleaning the inner surface to prepare for the new core.
• Dry fit the new core material into the cut-out area. Ensure it fits snugly and fills the space evenly. Mark the required size if adjustments are needed.
• Temporarily place weights, such as sandbags, on the new core to ensure it stays in place.

Wet the New Core with Resin:

• Mix epoxy resin with a hardener, following the manufacturer's instructions. Use epoxy resin instead of polyester resin for a stronger bond.
• Remove the weights from the new core.
• Apply a layer of neat (un-thinned) resin to the inner skin of the deck and the new core using a paintbrush or roller. Ensure both surfaces are adequately wetted out.
• Fit the resin-coated core into place, ensuring it adheres well to the resin-coated inner skin.
• Reapply weights to the new core to hold it firmly in place until the resin cures.

By following these steps, you will successfully dry fit a new core and wet it with resin, restoring the integrity and strength of your boat's deck.

Lay the mat and soak with resin

Once you have cut out the soft spot and weak areas, you will need to prepare the area for the new core. This involves cleaning the inside surface with a dewaxing agent such as acetone and grinding a slope into the surface.

Next, you will need to cut a sheet of countertop material that is slightly larger than the hole. This will be used to support the new core and fibre glass matting. Wax one side of the countertop material and spray it with a mould release spray before duct-taping it over the hole, with the waxed side facing the deck.

Now it is time to lay the mat and soak with resin. Pre-cut the fibreglass matting and cloth you will use to fill the hole. Don Casey, a boating expert, recommends beginning with "two layers of 1 1/2-ounce mat", then alternating the mat with 6-ounce fibreglass cloth. You will need one layer of fibreglass for each 1/32-inch of deck thickness, with each layer of fibreglass cloth and mat 1/2 inch wider and longer than the previous layer.

Mix the epoxy resin and hardener for the fibreglass. When it starts to harden, begin laying up the fibreglass and epoxy resin, three layers at a time, until the repair is complete. Press the fibreglass into the epoxy resin with a small paint roller or a squeegee.

Allow the fibreglass to cure thoroughly before removing the sheet of countertop material and walking on the repair.

Frequently asked questions