Sailing Zephyr IV · video

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EVA foam teak decking on Zephyr IV's bridge deck held up well for two years, but the caulking in the central panel turned sticky and shoe-fouling, requiring full removal and replacement.Watch The surrounding panels, caulked at the same time, remained sound, suggesting the central panel's Sikaflex may have been the wrong product type.0:41 Dave stripped the failed sealant using a screwdriver to break seams, then removed residue with a scrubbing pad and methylated spirits, followed by a spray-on kitchen cleaner wash.0:58 Seams were masked, cleaned with acetone, vacuumed, and re-caulked with SIS 440 deck sealant applied with a motorized sealant gun.0:53 The powered gun sped up the job but over-pressured sealant at seam ends, pushing it under the masking tape and widening those ends visually.1:53 After a month's cure, a Stanley knife trimmed the excess cleanly.2:13 The EVA foam itself showed no deterioration over the two-year period.0:28 Matching caulk product to the specific EVA foam application matters; switching to SIS 440 and a motorized gun resolved both the adhesion failure and the application speed problem.

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