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Author Topic:   Repair Front Deck Storage Cover

Smithsm posted 05-18-2009 03:05 PM ET (US)
On my 1998 Outrage 20 the hinged deck cover for the front dry (wet?) storage box (not the anchor storage) has delaminated in the port stern corner - the corner closest to the hinge.
It is soft inside.
I was planning on diggin it out, filling it in and epoxing it. The other alternative is to dig it out and put in sold fiberglass and resin. the edge of the gel coat is cracked but it is minor.

any suggestions before I begin glueing and clamping ?
thanks
deepwater posted 05-18-2009 06:48 PM ET (US)
Try to determine what caused it to fail and fix that first or a solid repair will only cause the damage to move further down the cover
Smithsm posted 05-18-2009 08:31 PM ET (US)
[Having] not owned the boat it is not possible to figure out what caused the failure. [It] is in a easy clear drainage spot, so it is not sitting in water. [It] does show some sign of trauma so I figure it got pried shut with something near the hinge that caused the trauma, then it got water inside, but this is just a guess
deepwater posted 05-19-2009 06:19 AM ET (US)
So something might have gotten under the hinged area and than was stepped on or someone was standing on that corner and the cover was raised
Phil T posted 05-19-2009 08:24 AM ET (US)
I had the same problem on my bow locker cover. A total lack of sealant in the hinge screw holes led to the wood perimeter frame and balsa like core in the bottom corner to rot.
I dremelled off the delaminated fiberglass and cleaned out the rot. Filled the voids with Marine Tex. I also covered the "green line" of exposed fiberglass around the bottom of the hatch and calked the screws.
Smithsm posted 05-20-2009 10:13 AM ET (US)
Deepwater
yes - that was my guess based on there the small break in the fiberglass is located. [The] break is in the SIDE of the hatch near the hinge area on the after side. [But] now that I have read Phil T's comments my bet is that what happened to him happened to me, and the crack came later after the structural integrity was lost. Essentially once the core was rotted it was too weak to sustain normal stress and the fiberglass lacked the structural integrity so it cracked. [Sounds] like I will be doing the surgury that Phil T did, rather than buy a new hatch.
deepwater posted 05-20-2009 10:51 AM ET (US)
If your going to dig or core it out might i suggest drilling into and gluing pins or dowels back into the cover mass ,,It might give you more strength in a weak area
Smithsm posted 05-21-2009 07:30 AM ET (US)
[Thanks] for the suggestions. [Right] now my plan is to reinstall it for the fishing season and do the work over the winter. [All] suggestions, ideas and experiences welcome on this one. It won't be pretty to have to pull apart this item as it is only cracked and open in a small section, but the rot seems to go deeper. [Maybe] an expanding foam would work if I can dig out the rot.
deepwater posted 05-21-2009 09:24 AM ET (US)
Expanding foam will fill but it will not support or strengthon the area so if it gets worse remove the cover
Smithsm posted 05-22-2009 08:38 AM ET (US)
I carefully evaluated the cover.
I understand now why it cracked - the core rotted and it lost strength - the fiberglass was not strong enough without the core.
My options are to dissasemble very carefully and rebuild or buy a new one. After I call whaler and find out I can't afford a new one I will rebuild.
I will probobly have to use a dremel to carefully seperate the top from the bottom.
then I need to decide what to put back into it. I am leaning towards lateral (port to starboard) support ribs - treated lumber ??? starboard strips epoxied in??? or perhaps several layers of good old mat and fiberglass that will incrase the weight.
I will also research this topic on this web site. this appears to be anothe whaler flaw so others will certainly be dealing with the same problem.
as always- input is very welcome..........

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Author	Topic: Repair Front Deck Storage Cover
Smithsm	posted 05-18-2009 03:05 PM ET (US) On my 1998 Outrage 20 the hinged deck cover for the front dry (wet?) storage box (not the anchor storage) has delaminated in the port stern corner - the corner closest to the hinge. It is soft inside. I was planning on diggin it out, filling it in and epoxing it. The other alternative is to dig it out and put in sold fiberglass and resin. the edge of the gel coat is cracked but it is minor. any suggestions before I begin glueing and clamping ? thanks
deepwater	posted 05-18-2009 06:48 PM ET (US) Try to determine what caused it to fail and fix that first or a solid repair will only cause the damage to move further down the cover
Smithsm	posted 05-18-2009 08:31 PM ET (US) [Having] not owned the boat it is not possible to figure out what caused the failure. [It] is in a easy clear drainage spot, so it is not sitting in water. [It] does show some sign of trauma so I figure it got pried shut with something near the hinge that caused the trauma, then it got water inside, but this is just a guess
deepwater	posted 05-19-2009 06:19 AM ET (US) So something might have gotten under the hinged area and than was stepped on or someone was standing on that corner and the cover was raised
Phil T	posted 05-19-2009 08:24 AM ET (US) I had the same problem on my bow locker cover. A total lack of sealant in the hinge screw holes led to the wood perimeter frame and balsa like core in the bottom corner to rot. I dremelled off the delaminated fiberglass and cleaned out the rot. Filled the voids with Marine Tex. I also covered the "green line" of exposed fiberglass around the bottom of the hatch and calked the screws.
Smithsm	posted 05-20-2009 10:13 AM ET (US) Deepwater yes - that was my guess based on there the small break in the fiberglass is located. [The] break is in the SIDE of the hatch near the hinge area on the after side. [But] now that I have read Phil T's comments my bet is that what happened to him happened to me, and the crack came later after the structural integrity was lost. Essentially once the core was rotted it was too weak to sustain normal stress and the fiberglass lacked the structural integrity so it cracked. [Sounds] like I will be doing the surgury that Phil T did, rather than buy a new hatch.
deepwater	posted 05-20-2009 10:51 AM ET (US) If your going to dig or core it out might i suggest drilling into and gluing pins or dowels back into the cover mass ,,It might give you more strength in a weak area
Smithsm	posted 05-21-2009 07:30 AM ET (US) [Thanks] for the suggestions. [Right] now my plan is to reinstall it for the fishing season and do the work over the winter. [All] suggestions, ideas and experiences welcome on this one. It won't be pretty to have to pull apart this item as it is only cracked and open in a small section, but the rot seems to go deeper. [Maybe] an expanding foam would work if I can dig out the rot.
deepwater	posted 05-21-2009 09:24 AM ET (US) Expanding foam will fill but it will not support or strengthon the area so if it gets worse remove the cover
Smithsm	posted 05-22-2009 08:38 AM ET (US) I carefully evaluated the cover. I understand now why it cracked - the core rotted and it lost strength - the fiberglass was not strong enough without the core. My options are to dissasemble very carefully and rebuild or buy a new one. After I call whaler and find out I can't afford a new one I will rebuild. I will probobly have to use a dremel to carefully seperate the top from the bottom. then I need to decide what to put back into it. I am leaning towards lateral (port to starboard) support ribs - treated lumber ??? starboard strips epoxied in??? or perhaps several layers of good old mat and fiberglass that will incrase the weight. I will also research this topic on this web site. this appears to be anothe whaler flaw so others will certainly be dealing with the same problem. as always- input is very welcome..........