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The owners of an Outremer catamaran are performing extensive structural repairs on the deck to eliminate water ingress points and reinforce hardware mounting locations. The project involves removing stanchions, cleats, and lifting points to address localized wood rot and improve the integrity of the deck core. After drilling out existing holes with a hole saw, the crew fills the voids with epoxy resin reinforced with wood flour to create solid inserts for hardware mounting. They are installing custom-fabricated plywood backing plates inside the hull to distribute loads more effectively than the previous configuration. The team plans to replace existing stainless steel lifelines with Dyneema and is considering adding a gate to improve access while at anchor. All repaired areas are being faired with epoxy-based filler and sealed with an epoxy primer to protect against UV damage before final painting. The work requires a systematic approach, addressing one side of the boat at a time to maintain structural alignment. Proper preparation of the substrate and the use of structural epoxy fillers ensure long-term durability for the hardware mounts.

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