Well today saw us taking more of the saloon deck apart. It was slightly disappointing in that we had hoped to retain some of the teak planking to use again. However because it had all been fastened with epoxy resin the wood split before the joints broke. Almost everything will have to be junked.
The plywood beneath the teak is completely rotten, as we knew, and we have just hoovered everything up as we have gone.
Unfortunately the lovely teak edging strip around the cabin top has also disintegrated to the point where it is unlikely to be usable. Similarly the companionway hatch frame has broken apart and we are going to have to completely rebuild that too.
To cap it all the roof of the saloon is made of two layers of fibreglass with a layer of balsawood sandwiched in between. Because the water has been getting in and has seeped throughout the structure, the balsawood has also rotted.
The only solution to this is to cut off the entire outer layer of GRP in one, hopefully, single sheet peel it off, clean up all the rotten balsa wood and replace it with new. We will then have to stick it down with resin and put the sheet of old deck back in place weighting it down until it set.
This will then provide a solid structure upon which we can lay our plywood upon which we can put new teak or perhaps the same plastic material we have used for the main deck.
The wonders of boatbuilding never cease but I can tell you the number bonfires has not yet come to an end. This is all a bit of a nuisance. However by the time we have done all this saloon will be stronger than it has ever been since it was first built.
This whole project, especially the fibreglass bit, is testing my knowledge and ability and the bank balance.
Thank goodness for Boatworks.com on YouTube.