Fly-bridge re-core
The top fiberglass had delaminated from the core on the flybridge in a few spots so it was time to re-core. I used a circular saw with a vacuum attachment to cut out the top layer of fiberglass. Because it was delaminated it came off very easily. I found foam core underneath, not the original balsa core. The foam was dry but whoever re-cored it did not do a good enough job with the epoxy and it separated.
The foam core also came out very easily. I used a scraper, then a oscillating tool, and finished up with a sander. I also supported the floor with 2x4s in the salon below.
I used balsa core that I got from Jamestown distributors in Rhode Island. It was very easy to work with and very easy to cut and fit into the space.
I used West System epoxy and hardener. I spread it out below the balsa core and after setting the core in place I weighed it down overnight with heavy water jugs. I filled the edges with more thickened epoxy and then used three layers of fiberglass on top of the balsa. I did some fairing around the edges and low spots.
After sanding I applied Kiwi Grip non skid. I had used it before on the fly bridge and it performed very well. I did two coats of Kiwi Grip.
The new Kiwi Grip blended very nicely with the old Kiwi Grip and is a good look on the fly bridge.
