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.