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Author Topic:   18' Outrage deck softening
johnwedwardsjr posted 06-30-2003 11:05 PM ET (US)   Profile for johnwedwardsjr   Send Email to johnwedwardsjr  
The deck on my 1987 18 ft. Outrage has softened to the point that the chairs are not stable. How can this be repaired? Is their wood under the deck to support the gas tank? I am also interested in sources for new and used whaler parts. Thanks in advance for sharing your knowledge. If you are aware of a person or company in GA that can handle this repair for a fair price, please share their contact info too.

This request was aslo posted in another section by mistake.

dfmcintyre posted 07-01-2003 08:57 AM ET (US)     Profile for dfmcintyre  Send Email to dfmcintyre     
John - the area that is softening the fuel tank cover or the rest of the deck?

If it's the tank, it's much easier to repair.

In brief:

Cut or score the clear plastic caulk that runs the perimeter of the tank cover and unscrew all the stainless screws holding it down. Remove the cover and flip it over on two or three sawhorses. You'll see how the cover is made, with fiberglassed encapsulated plywood as the structural member.

At this point, you could either take it to a decend repair facility (hint...look for an automotive repair shop that specializes in Corvette repair, if you can't find a good marine repair shop in your area) or do the repair yourself.

Keeping in mind that it's not brain surgery, you can cut open the fiberglass with a good carbide blade circular saw, set to minimal depth. Gut all around the builtup area. Pry open that area and scrape out the rotted wood and replace it with a piece of plywood of the same thickness and size.

Rough up the cutline edges with 60/80 grit to allow the new resin to stick and clean well. Cover the entire new plywood surface with epoxy (I prefer the West system brand) and two coats of fiberglass, cut to overlap slightly the cut lines.

Paint or gelcoat, your preference, since it's not going to be seen.

I've glossed over some details, but if you can get ahold of a fiberglass repair manual, it will be a big help. Again, the West Epoxy System has some manuals and videos on this.

Good Luck! Don

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