Rotted core and fiberglass repair with new honeycomb core

There was some rotten core in a section of deck and one of the engine room covers. The boat is made of a wood core with fiberglass on each side of the core. This makes a very strong structure, but any break in the fiberglass skin can let water in and eventually rot some of the core material. When this happens, the deck feels soft and spongy when walked on.
Repair is a lot like getting a filling at the dentist. You cut away a little bit, and a little bit more until you are past all the rot so your repair bonds to solid material on all sides. I replaced the old core with a plastic honeycomb material which can never rot, and then covered my repair with fiberglass.
Holes in the engine room hatch cover were covered with painters tape so a mix of resin and glass fibers could be spread into the hole from the back. The tape becomes a mold to shape the other side of the repair to match the top surfaces of the hatch.

Пікірлер: 89

  • @pigfigjig
    @pigfigjig2 жыл бұрын

    Mate you are so easy going that now all i can think about is fishing and smoke.. Thankyou for your legendary fibreglass tech and prac🙏❤️👍

  • @not2late2game53
    @not2late2game535 жыл бұрын

    It amazes me that near 24,000 views only 206 gave a "thumbs up" of appreciation for the skill, depth of understanding, and detailed explanation FOR YOU (also the video+editing) FOR YOU. Watch it again - play it slower if you have to, but this is transferable information to jobs beyond boat repair. I enjoyed the heck out of it.

  • @csvscs

    @csvscs

    5 жыл бұрын

    The dude has no regard for safety

  • @todddorsey1150

    @todddorsey1150

    5 жыл бұрын

    @@csvscs get over it.

  • @deweypug

    @deweypug

    5 жыл бұрын

    There is also some major errors in the way he 'repaired' the first hole... the core should have been clamped in for proper adhesion (to remove air bubbles) before he began laying in the top layers. He also did not follow the 6:1 feathering over the repair for proper adhesion and strength.

  • @todddorsey1150
    @todddorsey11505 жыл бұрын

    Thank you sir....for showing us who are less knowledgeable how to do glass. Your videos are narrated excellent, with step by step. I enjoy watching you work on your projects. Stay well.

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    5 жыл бұрын

    Thanks, I don't really know how to do any of this. I just bought the stuff and went for it after watching a few youtube videos. Hope some of the info is useful to others who are also just beginning their boat adventure.

  • @br5498

    @br5498

    4 жыл бұрын

    Go watch "Boat works today" to learn the right way.. this isn't...

  • @cccreations5478

    @cccreations5478

    4 жыл бұрын

    @@br5498 How do you think boat works learned,he is simply a DIY'er just like this guy, by no means was he anywhere close to being a professional, just some guy learning as he went along day by day,he even stated that in his videos. you might want to learn a little more yourself before being so harsh in judging others who are learning. Yes he done nice work,and this man is to, and learning as he goes, so you might try learning to be more humble!!

  • @alexbowie6316
    @alexbowie63165 жыл бұрын

    I was actually waiting for your hair to get laid up! lol. Good work and patience there.

  • @paulrock8571
    @paulrock85714 жыл бұрын

    Great Video... a whole lot of love going into that boat... all are right... get yourself a good respirator and wear it so when you get that queen finished you can enjoy it for many healthy years...

  • @soylentgreen2065
    @soylentgreen20655 жыл бұрын

    Thanks for taking the time to video these repairs...very interesting

  • @mwatkins2464
    @mwatkins24645 жыл бұрын

    You did a good job I thought you wouldn’t get all the air out without using a fin roller but it looked like you got it all out ! Great job man 👍👍👍

  • @brianstone3972
    @brianstone39722 жыл бұрын

    Wow this was a great video I learned a lot. Thanks for sharing!

  • @DougKoper
    @DougKoper5 жыл бұрын

    Skilled glass repair thank you.

  • @wabbott444
    @wabbott4445 жыл бұрын

    Well narrated video!

  • @mohdzakiabdulrahman7270
    @mohdzakiabdulrahman72704 жыл бұрын

    Good work..atleast i know what to do now ..if i need minor repair on my boat..god bless you cheer bro..from Malaysia..

  • @ericmoody3944
    @ericmoody39446 жыл бұрын

    That is dedication, good job!

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    6 жыл бұрын

    Thanks! There is usually some glass repair any time you get a good deal on an older boat. If you are interested, some of my earlier videos about fixing the sailboat have more fiberglass repair that do not involve core material.

  • @paulskinner5567
    @paulskinner55674 жыл бұрын

    Good job mate!!!!

  • @joellazo1651
    @joellazo16515 жыл бұрын

    A nice job man way to go

  • @stevenr8606
    @stevenr86063 жыл бұрын

    Glassing on gelcoat??? 😳 Way to much FUN 🤯

  • @petec9686
    @petec96863 жыл бұрын

    If you had the time, you could have drilled a bunch of tiny holes in the good part of that engine cover and threw it in the lake for a week. The fiberglass panel would have jumped right off.

  • @dalesmth1
    @dalesmth15 жыл бұрын

    Nice work. But, never cut square corners on a repair. As it can allow cracks to form later. Use a hole saw for a 1 to 2 inch radius on the corner, depending on the size of the repair.

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    5 жыл бұрын

    Nice to know, thanks. I'm doing a lot of learning as I go, so any helpful advice is greatly appreciated.

  • @Bakanelli

    @Bakanelli

    Жыл бұрын

    Meeh I didn’t see Boat Works Today do it and hes the most attention to detail guy I ever saw period. Also wouldn’t bother cos it creates problems at the point when you would refit the cut out portion of glass. Of course you wouldn’t cut out many small parts of the glass in the first place like in this video but rather one big chunk

  • @Bakanelli

    @Bakanelli

    Жыл бұрын

    7:49 why in the name of the lord don’t just remove the rotten core and leave the good stuff in ?! ☹️

  • @jerryparks9838
    @jerryparks98385 жыл бұрын

    I know you're now working on your trawler and doing major addition and remodel to it how about letting us know how things are going would love to see a video to see where you're at with that thanks so much for your hard work making your videos I like your videos much more than the regular sailing channels miss your videos very much so how about a new one

  • @swaybelly3212
    @swaybelly32125 жыл бұрын

    I think I got a contact-high just watching this....

  • @notwhatiwasraised2b
    @notwhatiwasraised2b5 жыл бұрын

    Imagine the next person chipping out that core

  • @jerryparks9838
    @jerryparks98385 жыл бұрын

    Where did you go love your videos miss them very much how about a new video

  • @silvanomoreira5407
    @silvanomoreira54073 жыл бұрын

    Hello, I am thinking to have a small sauna in the after kabin of my glass fiber sailboat? May this project go well if I investering in a proper isolation? Or it that just an insane idea?

  • @felipefelipe4842
    @felipefelipe48425 жыл бұрын

    Need a roller. I think that would help.

  • @rastagrastag9496
    @rastagrastag94964 жыл бұрын

    How is the honey comb holding up?? Do you have much flex when walking on the hatch? Was it a expensive material to use ?

  • @davidwelch9658
    @davidwelch96584 жыл бұрын

    Maybe a workbench should be the next project. That's got to be hard on your knees and back working on the ground like that.

  • @shanebeaudrot777
    @shanebeaudrot7775 жыл бұрын

    Ok, and don't call me Matt. Rotten to the core? All joking aside, good video.

  • @jokingz1
    @jokingz16 жыл бұрын

    enjoyed your informative videos. what did you do with the Mac 25 sails?

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    6 жыл бұрын

    I still have the Mac 25. Its unofficially for sale if anyone is interested. I have two main sails and three jibs, so if you want a set of sails I can sell one set separately. I'm also planning on selling the new Suzuki outboard separately and selling the boat with the original Johnson sailmaster 2-stroke unless someone wants a package deal with the brand new 2017 motor and 2017 trailer. email Sciencelookers@aol.com if interested. Another option is the little Harbor freight generator which can run the fridge or microwave, or the larger Honda generator which can run the air conditioner without shore power, or no generator if you plan to live in a marina with shore power.

  • @ClinToneCust23
    @ClinToneCust235 жыл бұрын

    where did you get your honeycomb plastic board?

  • @felipefelipe4842
    @felipefelipe48425 жыл бұрын

    I have a question about the first repair you did in the video. I see you cleaned out a hole and filled it in so, my question is if you want strength why not open up more of the hole area to make the cloth overlap onto good wood? I would think bonding to good material would strengthen the patch you made. I can't see tearing the cloth as I want all the strength that I can get. Can you comment?

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    5 жыл бұрын

    You're right, the repair might have been stronger if I laid glass over a larger area. The end-grain balsa comes out real easy where it is wet, but where it is still intact, it is almost impossible to separate the layers of glass from the balsa core. You can see this when I try to peel the back off of the engine bay hatch. When the boat was made, resin seeped down through the end grain like it was made of thousands of tiny straws with the open ends where the fiberglass was laid on top. All that resin infiltration into the wood makes it really strong and really hard to peel the fiberglass skin off. Where I did the first repair on the top of the side of the boat, I cut away until there was just a little of the good core, and managed to chisel away just the very edge of the good core without too much difficulty. If I had tried to continue peeling, it would have been like the hatch cover, where I had to dice it up with the circular saw and chisel out tiny cubes of core. Where that repair was made, there was fiberglass below and above the core. I left the glass below intact, and glued the new honeycomb core to that before laying the new glass over the top of everything. I don't think its going to crack or break. There are a lot of layers of fiberglass on the repair before I get to the torn chopped strand mat. The final layers were torn so the edges would feather gently instead of having a big cliff where the chopped strand mat ends. This makes fairing easier and thinner. Its a trick I saw on KZread channel "Boatworks Today" which is really good for learning to do fiberglass work. I watched a bunch of videos and then sort of made stuff up as I went. I'm sort of learning by experimentation and going with what seems to work best for me. I bought several fin rollers, but they only work if you go real slow with them. Because I don't know what I'm doing, I found that I could get all the air out of the lamination by stippling with the brush in fast, straight up and down motions, driving the bristles straight down into the cloth. It doesn't remove excess resin like the fin roller does, but made an acceptable repair without any air bubbles trapped between the laminations. I was able to lay down at least a half dozen layers in one afternoon going wet on wet, then letting the whole thing set up. Definitely not the recommended way, but it seemed to work well enough for me.

  • @ravenfeather7087
    @ravenfeather70875 жыл бұрын

    I've been using fiberglass occasionally for automobile body work for a number of years. But recently built a pop-up top on the cap of my pick-up to give me more headroom. I have a little cot in it and use it for camping and sleeping when I'm traveling. I was amazed at how much adhesion and cohesion fiberglass resin and matte has. TOUGH stuff with a lot of structural stability when applied to wood and sanded fiberglass and gelcoat. What is the name of the honeycomb material you used? Where did you purchase it?

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    5 жыл бұрын

    I think its called Nidacore. I got it at a place called Fiberglass Florida in Rockledge Florida. It comes in big sheets 4 feet wide and I think 8 feet long. If you're not near me, look for fiberglass supply places near you, otherwise shipping is going to cost a lot. That stuff is amazing. Its kind of flexible until you laminate a layer of glass cloth to each side, then it gets extremely strong. I had a part where the laminating had some dry layup so I made another part. I need to fix the swim ladder on the boat and wondered if I could use some of the nidacore with glass cloth laminated to both sides. As a test, I took the bad part and used it to bridge between two 2x4's. The 2x4's were about 18 inches apart and the nidacore part had a skinny section in the middle about 2 inches wide and the core was one inch thick. I stood on it, expecting it to break but it didn't. Then I jumped up and down on it and it still didn't break. It is incredibly strong and feather light. The nidacore has a fuzzy layer on each side. When resin gets into all the fuzzy fibers it has very good adhesion. With glass laminated on each side, it can't flex without stretching one side and compressing the other, and the glass is not going to stretch even a little bit. I'm making a shelf to go on top of the transom of the boat. There is a small enclosure that goes on top of the shelf which will hold my generator. There are four nidacore vertical supports tabbed to the transom with glass cloth tabbing going out about 3 or 4 inches on each side of the supports. I am relying on adhesion of the resin to the sanded transom fiberglass to keep the shelf and generator from falling off of the boat. If you have enough surface area for your tabing, it should be as though it is an integral part of the hull. Sand the area with 40 grit, wipe down with acetone, and the resin should get a really good grip on the rough, clean surface. I haven't been posting videos for a while so I could learn to use these materials before posting. I didn't want to be one of those people who post videos of the first time I try something and then another video later saying not to do what was shown in the first video. There will be a mini-series of videos about working with honeycomb core when I am done with these first few projects. I plan to do more extensive work with nidacore and fiberglass but decided to do several small projects first so I could learn on some small, relatively unimportant parts before doing any large projects with it. Glad to see you subscribed. Ring the bell to be notified when I post new videos. The mini series about working with honeycomb core will be posted soon. I couldn't find many videos about how to use it, so I hope the mini-series will be a helpful resource for others who want to use it to fabricate new structures.

  • @xs10z

    @xs10z

    2 жыл бұрын

    > I was amazed at how much adhesion and cohesion fiberglass resin and matte has Pound for pound, properly laid fiberglass is stronger than steel or aluminum.

  • @Beachnative42
    @Beachnative425 жыл бұрын

    Why not buy a roller to minimize your resin to glass ratio ?

  • @user-ym9wb2mk5e
    @user-ym9wb2mk5e4 жыл бұрын

    Hi. Where did you get the honeycomb sheet at? Looking online, it's actually pretty expensive!

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    4 жыл бұрын

    I got the honeycomb at Fiberglass Florida in Rockledge, Florida. I picked it up myself. I have a utility trailer that I bring when I need full sheets. If I know I need to cut some specific sized panels, I can sometimes cut the sheet right in their parking lot using a razor knife like you'd use to cut carpet. Then the smaller pieces can go in my car so I don't need to bring the trailer. If you want your panels to be more precise than mine usually are, cut oversized pieces with the knife, just cutting the sheet into panels that fit in your car but not attempting to cut the precise size or shapes needed. Then cut final shape with circular saw running alongside a straight board you clamp or tape down after you get home. I have a sheet of 2 inch styrofoam I got at home depot that I put below the honeycomb I'm cutting so the saw doesn't hit the concrete driveway below. One sheet of foam lasts a long time and I cut lots of panels on it.

  • @sunilkumararickattu1845
    @sunilkumararickattu18455 жыл бұрын

    Are u using PU Resin or Epoxy resin? Totally confused?

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    5 жыл бұрын

    I use polyester resin and gelcoat for everything. I sometimes refer to thickened resin incorrectly as "thickened epoxy", but its actually all just plain old polyester resin, chopped strand mat and woven glass cloth. I use whatever thickening agent they have at the fiberglass shop when I want to thicken it.

  • @deweypug
    @deweypug5 жыл бұрын

    A few comments that really are meant as questions rather that criticism... on the first rotten area, I'm very concerned that the core that was placed in was not clamped in to remove air bubbles... no matter how much resin was applied, it will tend to 'float' in that pool of resin, rather than 'bonding' to the substrate. The other concern is there should be a 6:1 area feathered in to the gel coat over the repair for proper adhesion and strength.. Let me know what you all think.

  • @duncanrose3891
    @duncanrose38916 жыл бұрын

    Thanks for the video. Please take care of your own health tho. Glass dust is bad, acetone on skin is bad too.... Not criticising, just concerned. :)

  • @01MIDWAY
    @01MIDWAY5 жыл бұрын

    Flipp Flops?

  • @TheunisSnyman
    @TheunisSnyman4 жыл бұрын

    Where can I find the honeycomb core. Thanks

  • @willeywashington1284

    @willeywashington1284

    4 жыл бұрын

    I've bought some on E-Bay

  • @Rick-tb4so
    @Rick-tb4so Жыл бұрын

    Why did they ever use core that would rot ??

  • @crdorado1195
    @crdorado11954 жыл бұрын

    Hey, where are your vids? Are you on a hiatus? Come on back, your content was really good.

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    4 жыл бұрын

    There are a few more videos from cruising on the boat, then the videos will get back to more fabrication jobs. Coming up will be an even larger solar panel rack covering the front of the boat with 3,000 watts of panels instead of the three bimini tops. There will be some massive lithium batteries to go with the new panels and all the wiring for that. A new fiberglassing project will add to the outside of the hull, increasing the boat's buoyancy by 2,000 pounds. There will be a new duct that lets a window air conditioner hide inside the front of the flybridge and send cool air into the deck hatch over the sofa, and a cool nidacore table that sits on top of the duct that lets the honeycomb pattern show through clear epoxy. The undersides of both solar panel racks get ceilings with recessed LED lighting made out of the same honeycomb panels with clear epoxy that lets the honeycomb pattern in the core show through. The entire back cabin is ripped out while the new batteries are being installed. There will be the freezer, a new refrigerator, and a new countertop in there. So those are some of the projects that will happen over this winter once the cruising videos are all uploaded. There will also be some restoration of a 32 foot catamaran. Hope you enjoy!

  • @glassman51
    @glassman515 жыл бұрын

    You need to check out “Boatworks today” so that you can learn to do proper fiberglass and Core repair, Protect your lungs...

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    5 жыл бұрын

    I've watched some video on that channel, its great, thanks. I usually wear a respirator when I am not talking to the camera.

  • @Imwright720

    @Imwright720

    5 жыл бұрын

    His fiberglass repair looks fine.

  • @gilbertodiaz-castro626

    @gilbertodiaz-castro626

    5 жыл бұрын

    Gene Miller if he doesn't extend the fibers past the patch to the surrounding surfaces that patch WILL eventually break off because of the straight breaks without fibers between the honeycomb and old wood. He could've cut the honeycomb filler with beveled edges and gotten a stronger joint.

  • @bondvagabond42

    @bondvagabond42

    4 жыл бұрын

    @@gilbertodiaz-castro626 at about 7min mark they have several layers of the chopped strand mat bridge the gap from the repaired section to existing section. You are right, it would be stronger to have every layer of glass bridge the gap, but if max strength is wanted, only epoxy should be used on a repair. Polyester resin isn't very strong when stuck to cured polyester resin. It's fine in a wet layup, where each layer is added to a tacky, uncured layer beneath though. A benefit to the method in the video, would be, it is easier to match the lines of the boat with the repair. A hybrid method that works is to replace in a "brick" without overlap like in the vid, then dish out the seam and put your layers of glass in to bridge the gap. For ultimate cheapskate method, without sacrificing strength, I try to cut a big piece of skin off, so I know I'll get past rotten core, then I replace core, reuse original skin, then feather edges of seam to get a good strong overlap with many layers of fiberglass. You can dodge molded grip pannels in the deck that way, and is way easier than matching no-skid pattern if you don't do it every day, lol. Is it stronger than it was with rotten core pre-repair? Definitely. Is it strong enough? Probably, it was repairing rot not an area of mechanical failure, and there aren't any force concentrators there like bolted hardware or anything.

  • @Wellorep
    @Wellorep3 жыл бұрын

    Dude.. I have had long hair .. if I'd have been laying glass with my wispy hair jung hanging out there, it would have been glassed to the boat at some point.

  • @striper2300

    @striper2300

    3 жыл бұрын

    hair and tie dye he's left over from the 60's I guess

  • @marknusbaum3946
    @marknusbaum39463 жыл бұрын

    Here's how I f'd up some fiberglass. I don't recommend anyone try this without the protective long hair and flip-flops and hey dude did you bring a doobey? I'd be alot cooler if you did....

  • @garyricky8744
    @garyricky87445 жыл бұрын

    How much did you get in your hair ?

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    5 жыл бұрын

    A little bit but not as much as you'd think from watching the video.

  • @tuannguyenanh5224
    @tuannguyenanh52244 жыл бұрын

    I at home Việt Nam,i loves video is Sir and love ship,I love amazing ship ,Mr sovernie ship to HaNoi City Việt Nam ,I Thanks You

  • @notwhatiwasraised2b
    @notwhatiwasraised2b5 жыл бұрын

    No dust collection...no mask...you may pay dearly for that before long

  • @MrCt333
    @MrCt3336 жыл бұрын

    Be careful sanding fiberglass without a respirator...

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    6 жыл бұрын

    Thanks, most of the time I have one on.

  • @MrCt333

    @MrCt333

    6 жыл бұрын

    Good to hear, I've got a 73 Pearson 30 that I need to do quite a bit of fiberglass work to so I appreciate all of the videos. All of my stanchions and most anything that goes through the deck. Hopefully if I learn how to do it I can save myself some money.

  • @dale3858
    @dale38585 жыл бұрын

    For your health you should be wearing gloves when using acetone.

  • @jonnyy4088
    @jonnyy40885 жыл бұрын

    I'd replace your saw flex.That's electrocution waiting to happen.

  • @howard977
    @howard9775 жыл бұрын

    O

  • @phillipr6676
    @phillipr66765 жыл бұрын

    Gollum???

  • @nasanction

    @nasanction

    5 жыл бұрын

    It was an insensitive reference to the creature in Lord of the rings. Partially why Cal./N.Y.C./Ill. decay more and more every day. Live and let live people!

  • @1972erdnaxela

    @1972erdnaxela

    5 жыл бұрын

    No, just a human living in a very beautiful way!

  • @ggzzlittle

    @ggzzlittle

    5 жыл бұрын

    There will always be a duesh

  • @youyouulf
    @youyouulf4 жыл бұрын

    Wow... this repair is not how to do it. This video should only tell the story about how you did your so called repair. The message to your viewers should be "Do not ever copy this method"! Folks, do your researches on reliable sites, like Boatworks Today or Sail Life.

  • @georgemulligan8958
    @georgemulligan89585 жыл бұрын

    Get a haircut it's not the sixties

  • @ninehundreddollarluxuryyac5958

    @ninehundreddollarluxuryyac5958

    5 жыл бұрын

    I'm not a hippie, I'm a hermit.

  • @stevekyle4371

    @stevekyle4371

    5 жыл бұрын

    Dudes mad, he's probably bald.

  • @nasanction

    @nasanction

    5 жыл бұрын

    What difference does it make? You don't have to wash it. Live and let live...

  • @ravenfeather7087

    @ravenfeather7087

    5 жыл бұрын

    Up yours, George. What he does with his hair is none of you business.