Day 2 - Recore Stbd Cockpit

Continuing from where I left off yesterday, the weather was warm again and supported more core work.  The first thing accomplished was removing the plastic used to squeegee the epoxy, then sanding with 60 grit paper to roughen the surface for a good mechanical bond.  The areas that were punched through on the bottom skin are now fully sealed inside the cockpit locker.

New Fiberglass sanded

 After sanding, I mixed up some Corebond (remaining from the transom recore) and used it to fill in the voids where core was removed around the lip that was cut using the Fein tool.  Corebond was then spread on  the new fiberglass using a disposable notched spreader.  This provides just enough filler to bond the balsa without causing lumps and voids.  Below is a photo with new core bonded.  It was worked in place by hand, and Corebond inserted around the edges with a spreader.

New core bonded

After the new balsa was positioned on the core bond, it was covered with plastic sheet and weights applied with constant pressure for the Corebond to catalyze.  The cure time at 55 degrees was about 40 minutes.  While this was curing, I over drilled and epoxy filled the holes for the hand rails, since these are being replaced over the winter with new Teak - thanks to Charlie Stoddard - Falcon.

Applying pressure during core bonding

Subsequent to curing, the weights were removed and the balsa sanded to make sure the final surface would be level with the surrounding area, since I planned on reusing the skin that was peeled off.

Core sanded / leveled for skin

 To bond the old skin to the balsa, I used thickened epoxy rather than the Corebond.  The Balsa was wet out with neat epoxy using a chip brush, as was the back of the old skin.  Epoxy was mixed and thickened with Colloidal Silica and Adhesive Filler to a mayonnaise consistency.  This was poured in the area and spread with a chip brush.  The old skin was beveled on both the top and bottom edges to allow the epoxy to flow, and permit fairing on the top surface.  The skin was put on top of the new balsa and pressure applied to make sure that voids were forced out.  A plastic sheet was put on the surface and weights applied similar to the method used with the balsa core.  Below is a photo after the old skin was bonded and the masking removed.  That will complete the work until the spring when final fairing, sanding and gelcoat will be applied.

Old skin bonded to new core