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 Catalina 25 Specific Forum
 cockpit floor repair		  New Topic  Topic Locked
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bouy
1st Mate

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33 Posts
Initially Posted - 07/15/2011 :  18:50:21  Show Profile
Looking for info on cutting out the cockpit floor and replacing the rotten wood. Has anyone tried this ? 1980 Catalina 25 SR/SK
81 sksr #1733
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Voyager
Master Marine Consultant

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USA
5379 Posts
Response Posted - 07/15/2011 :  21:15:25  Show Profile
I haven't done it but if I were to, my first approach would be to use the handle of a screwdriver to tap all around to find the worst spots, and work on those areas first. Unfortunately you may find as you go, you will find other soggy areas that sounded ok at first, but turn out to be bad on inspection. Again, you may wind up having to do the entire floor, but I would not assume so and begin in the "bad" spots.

I would begin any cutting from underneath the cockpit floor in the quarterberth area, so as not to make any noticeable cuts in the top of the sole. I would do it in cool weather, not 100+ degree weather in 110% humidity.
If however I found that I could not make this underneath approach work, I would work on top: set up a very fine sabresaw or dremel cutter with a very short blade and tape the sole right at the edge of the non-skid. I would make my incision right along the edge of the non-skid in the suspect areas.

If it turned out the entire cockpit core were rotten, then I'd try working it from the bottom. If you do this, make sure to cut out some plywood to lay down in the cockpit in case you need to walk through. If you were to remove the sub-floor, then try and walk on the sole, you might be in for an unfortunate surprise -- crack, crunch, oops! $%#@^!@#(*&$%@! broke through!

Some people have said its best to replace the core with new marine plywood, or some type of synthetic materials. 1" balsa might be hard to come by. Epoxy the replacement material in place underneath the sole. If you can do it as all one piece, that would be awesome. If not, you should try to use two long pieces side by side. If you need to use two pieces, create a tongue and groove along the mating edges of the wood to keep them together. Once you replace the entire core, then you must epoxy it to the bottom of the sole to seal it up. Afterwards, epoxy the skin bottom of the sole (in the quarterberth) to the bottom of the new core. You might want to place a strip of fibreglass cloth over the seam in the skin and epoxy that in place for strength. Fill the gaps with epoxy, but make it in small batches and watch out for drips.

You should also look to see what caused the balsa to rot in the first place. Do you have any holes in the floor, or in the seats, or does rain water invade your scuppers, the kickplates or lockers or the bilge pump handle gizmo?

For replacing core and epoxying skin, check out Don Casey's "This Old Boat" or another one of his <i>how to</i> books for tips on epoxy versus vinylester and how to cure the materials using saran wrap.
Edited by - Voyager on 07/15/2011 21:18:39
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Dave5041
Former Mainsheet Editor

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USA
3758 Posts
Response Posted - 07/16/2011 :  07:33:01  Show Profile
Few things are as much fun as laying fiberglass overhead.
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GaryB
Master Marine Consultant

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USA
4304 Posts
Response Posted - 07/16/2011 :  08:34:01  Show Profile
Use the search feature, someone did a nice write up on this with pictures a couple of years ago.
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Stinkpotter
Master Marine Consultant

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Djibouti
9081 Posts
Response Posted - 07/16/2011 :  09:38:16  Show Profile
Here's [url="http://catalina-capri-25s.org/forum/topic.asp?TOPIC_ID=22102"]one thread on the subject[/url], including a link toward the end to another resource. There are a number of other threads...
Edited by - Stinkpotter on 07/16/2011 09:38:42
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Notice: The advice given on this site is based upon individual or quoted experience, yours may differ.
The Officers, Staff and members of this site only provide information based upon the concept that anyone utilizing this information does so at their own risk and holds harmless all contributors to this site.