Living For Sail · video

What this video covers

Repairing a rotten sailboat deck requires removing damaged balsa core and replacing it with foam blocks bonded in thickened epoxy. To maintain structural integrity while working along the side decks, the repairer drives screws from the top down into existing headliner braces before removing the original fasteners. After clearing the balsa, the lower fibreglass skin is abraded using a seven-inch angle grinder with a 40-grit flap disc to ensure a strong bond for new 1708 fibreglass cloth. To improve epoxy distribution and minimise voids, the repairer cuts foam into smaller, 10-inch segments rather than one continuous piece, allowing for better "squish out" of the adhesive. A custom-rigged dust collection attachment on the grinder helps manage debris during the process. Using peel ply over the foam blocks creates a clean, ready-to-bond surface for subsequent layers, though applying adhesive to the peel ply can make removal difficult. Testing different foam-fitting techniques—such as ripping a ledge into the blocks—helps achieve a balance between a tight fit and sufficient space for epoxy saturation.

Boats in this video

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