Wildly Intrepid Sailing · video

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Repairing a waterlogged, delaminated locker door requires removing the rotten balsa core and replacing it with new material. After stripping the fiberglass skin, the process involves clearing out the mushy core using a chisel and scraper, then grinding the interior surface to reach bare glass.1:58 Because the original 3/8-inch core was replaced with 1/2-inch balsa, the new core pieces must be sanded or shaved down to fit under the existing fiberglass lip.13:02 To bond the new core, the repair uses polyester resin and multiple layers of chopped strand mat, which are cut rather than torn due to the thickness of the material.8:47 A cardboard template helps determine the fit, while thickened resin fills gaps between the balsa chunks.11:13 Tapering the edges of the original fiberglass skin ensures a stronger bond and a smoother transition between the old and new laminations.6:41

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