Core Questions

[s-dupuis]

I used a RotoZip tool to remove the outer skin on portions of my Typhoons side decks. The tool works like an end mill or a router. Setting the depth to 1/4" allows for careful removal of the outer skin. It's easy to control and you can make curved cuts and radiused corners.

I worked in 10" X 6" rectangular sections and easily peeled off the layer where the balsa was wet. In dry areas the bond was still very good. I left a 1" 'space' of original outer skin between each section to maintain a thickness level reference, but dug out all the wet balsa under the 1" spaces.

I noticed that in places adjacent to where I removed a section and stopped for that weekend, after 5 days exposed to the air, the balsa core was still wet within 1/4" of the edges of the fully exposed section.
Drilling test holes will tell you where the offending areas are but a pattern of holes will not get the moisture out. The refilled holes only act as little fiberglass 'pillars' when refilled, giving the false impression that the deck has integrity.

[Troy Scott]

s-dupuis,

After you replaced the wet balsa, how did you replace and/or reattach the original outer laminates?

[s-dupuis]

Troy,

The outer laminate was discarded. I replaced the wood and gradually built up the remaining height with resin, fiberglass roving and cloth. I would then cut out another 10" wide section 1" away from the previous repair leaving a strip of original outer laminate as a height reference (I dug the balsa out from under the laminate). I repeated the process as I went along.
The whole thing was later sanded to an even, consistent surface. My intent was to paint it afterward and add a non-skid surface but I sold the Typhoon for a CD22.

Steve

[Troy Scott]

Steve,

I was curious because I've heard of a repair method in which the original outer (upper) skin was successfully salvaged and scarfed back into the surrounding structure after replacing the wet balsa.

[Didereaux]

Troy,
Here is a link describing with pictures the whole process you are interested in.

http://www.triton381.com/projects/resto ... ecore.html

There are many more such projects this guy(Tim Lackey) has done on a Pearson Triton that he literally has brought back from Davy's locker.

g'Luk