1986 MONTAUK 17 Deck Repair

Repair or modification of Boston Whaler boats, their engines, trailers, and gear
tubbyama
Posts: 5
Joined: Wed Apr 26, 2023 3:35 pm

1986 MONTAUK 17 Deck Repair

Postby tubbyama » Fri Jun 02, 2023 6:32 pm

The previous owner of my 1986 MONTAUK 17 boat drilled a hole through the deck into the rigging tunnel for the fuel hose to pass through, but this hole is off centerline by an inch or two. The entire "core" is exposed in this hole. I plan to patch the hole.

Q1: how can I replace the missing deck?

jimh
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Location: Michigan, Lower Peninsula
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Re: 1986 MONTAUK 17 Deck Repair

Postby jimh » Sat Jun 03, 2023 6:04 am

For advice on making repairs to a Unibond hull of a Boston Whaler boat, see the FAQ at

https://continuouswave.com/whaler/reference/FAQ/

Read this answer

Q5: how is damage to a Unibond hull repaired?
https://continuouswave.com/whaler/reference/FAQ/#Q5

In the case of a circular hole in the deck that passes through an area where there is wood reinforcement, cut a suitable wood plug in similar wood--typically marine-grade plywood--using a plug-cutting tool. Install the wood plug into the hole and use wood adhesive to retain the plug, Then complete the repair of the hole using epoxy resin with filler material and possible a top coat of gel coat resin to obtain a good color match and UV resistance, if the location of the repair will be visible and exposed to sunlight.

If the area to be repaired is in the non-skid pattern area of the cockpit or deck, the gel coat resin surface area of the repair can be made using a non-skid mold pattern. You may be able to make your own non-skid mold pattern by taking an impression of the non-skid from another area where there is no damage.

For advice on how to take a pattern from a non-skid area, see this prior discussion:

Reproducing Non Skid Pattern
https://continuouswave.com/ubb/Forum3/HTML/014099.html

Also visit
Gibco FlexMold
https://gibcoflexmold.com/boat_manufacturer/boston-whaler/

Also, consider that if the existing hole in the deck will not be in a highly-visible area, there is really no need to restore the non-skid pattern.

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Phil T
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Location: Was Maine. Temporarily Kentucky

Re: 1986 MONTAUK 17 Deck Repair

Postby Phil T » Sat Jun 03, 2023 7:12 pm

Seal the walls of the hole with epoxy and add a deck grommet to cover the hole with a small cutout for the fuel line.
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