posted 03-23-2002 05:45 PM ET (US)
Dolphin - It is, or rather was, marine grade plywood. While the jury is out on using plywood, or a composite material like BW's Whalerboard, I think that your in for a transom redo. Mine ran in the neighborhood of $3000 - $3500, form what I recall (that price was included in a total reno project).
I don't really see how you could scoop out rotted wood from the top, working down. You could hit a portion of good wood, and still have bad wood underneath.
What the shop did with mine, was to cut a line with a carbide tipped router, the whole outer skin of the transom off. Then pealed off the skin, exposing the bad wood and some foam. This was all removed, and new multiple layers of marine grade plywood was epoxyed into place. The shop owner told me that there is more wood in the transom that was origionally installed.
They then layed up multiple layers of glass and resin, and finished it off. Identical from origional.
The owner also pointed out that much of the rot occurs from the breakdown of the origional bedding compound around the engine through bolt installation. Their way around it is to oversize the bolt holes, pour in resin and let set up overnight. The next day the proper sized holes are drilled. This way, there is a sold resin "plug" running the length of the bolt hole, which will not allow water to penetrate into the wood, even if the bedding compound breaks down over time.
Good luck -
Don