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1984 Revenge Deck Lid Repair
dave3825us	#1  Posted on 09/12/23 - 10:59 AM
Member Posts: 19 Comments: 1 Joined: 11/24/17	Wanted to know from those who have rebuilt Whaler deck lids, how far down do you go? Ripped off all the old wood and some spots it's down to the fiberglass skin and others its to the poly resin. I have more pics but cant figure out how to add them. dave3825us attached the following image: [76.82Kb] Edited by dave3825us on 09/12/23 - 11:02 AM
Phil T	#2  Posted on 09/12/23 - 3:57 PM
Administrator Personal Page Personal Album Project Albums Posts: 6991 Comments: 6 Joined: 03/26/05	Just remove the wood, leave the resin and glass. Add new plywood that is coated with epoxy. Overlap seams. Bevel edges and seal the end grain. 1992 Outrage 17 I 2019 E-TEC 90, Viper 17 2+ 2018 Load Rite Elite 18280096VT
dave3825us	#3  Posted on 09/12/23 - 7:15 PM
Member Posts: 19 Comments: 1 Joined: 11/24/17	I have read that people chiseled the wood but what's happening when I chisel the wood is its pulling the poly resin up off the glass. What is the best method for the rest of the wood removal? Sand it down until i hit resin? And this pic, that would be the resin with air bubbles? dave3825us attached the following image: [104.13Kb]
Joe Kriz	#4  Posted on 09/12/23 - 7:20 PM
Site Owner Personal Page Personal Album Photo Albums Project Albums Posts: 11434 Comments: 452 Joined: 03/18/05	Have you seen this article on our site? https://www.whalercentral.com/article...ticle_id=8
dave3825us	#5  Posted on 09/13/23 - 6:06 AM
Member Posts: 19 Comments: 1 Joined: 11/24/17	Joe Kriz wrote: Have you seen this article on our site? https://www.whalercentral.com/article...ticle_id=8 Yes , that's actually the first write up about deck rebuild I ever read. I also read this one. https://continuouswave.com/whaler/reference/centerDeckRepair.html I did not really see anything specific detailing how far to go. One concern I have is the condition of the poly resin. It has a ton of little cracks and voids in a bunch of different spots. Jeff used 3x 1/4 sheets and Jason used 2x 3/8 sheets, both equal 3/4 thickness. I have a 1984 Revenge and I think I have to exceed that because if I am seeing this correctly in Jeff's drawing, the first sheet of 1/4, that's in the skin, rests on the lip where the screws go. The second and third sheet, the remaining 1/2 inch, is that meant to rest on the top of the rigging tunnel and fish well wall? If so, my rigging tunnel sits between 11/16 and 3/4 lower than the lip as seen with the level and tape measure. Looking at my fish well lid, which has the same measured difference between the lip and the top of the rigging tunnel, that looks to be resting on both. dave3825us attached the following image: [51.54Kb] Edited by dave3825us on 09/13/23 - 7:50 AM
Phil T	#6  Posted on 09/13/23 - 5:32 PM
Administrator Personal Page Personal Album Project Albums Posts: 6991 Comments: 6 Joined: 03/26/05	Grind it down to the epoxy. You can fill the holes with a layer of epoxy, then apply the first layer of wood. 1992 Outrage 17 I 2019 E-TEC 90, Viper 17 2+ 2018 Load Rite Elite 18280096VT
dave3825us	#7  Posted on 09/23/23 - 12:54 PM
Member Posts: 19 Comments: 1 Joined: 11/24/17	Trying to determine if I can cut down a full sheet for the first layer as my lid measures 48 x 74. Full sheet is 48 x 96. The 2 articles I read both show using sections but I do not know if that's because their lids were larger than 4 x 8. I do not know the measurements of the Outrage lids. Only advantage using sections I can see is mixing smaller batches of epoxy at a time.
Phil T	#8  Posted on 09/24/23 - 7:19 AM
Administrator Personal Page Personal Album Project Albums Posts: 6991 Comments: 6 Joined: 03/26/05	overlapping sections adds strength. 1992 Outrage 17 I 2019 E-TEC 90, Viper 17 2+ 2018 Load Rite Elite 18280096VT
Phil T	#9  Posted on 09/24/23 - 7:20 AM
Administrator Personal Page Personal Album Project Albums Posts: 6991 Comments: 6 Joined: 03/26/05	The Outrage 22 cover is quite large and not possible from a full sheet of 4'x8'. 1992 Outrage 17 I 2019 E-TEC 90, Viper 17 2+ 2018 Load Rite Elite 18280096VT
dave3825us	#10  Posted on 09/24/23 - 5:50 PM
Member Posts: 19 Comments: 1 Joined: 11/24/17	Even tho I had the option to not use sections for the first layer, since my lid is smaller than a full sheet, I choose to use sections to allow a little extra time with the batches of epoxy, to fit exact and add weight. I have 3 sections ready but do not think I have enough filler so that's on its way. All that's really left is to tape up all though holes on the skin where any epoxy would run out. I have to ask, do sections add more strength than using a uncut piece?