Core material for deck

ABourgault

New Member
I know it's probably not worth the money or the effort but I like that kind of work and since my wife got the boat at 14 it has kind of sentimental value.

I started refurbishing our laser. It has been stored outside, upside down for 5 or 6 years. The deck was separating from the hull at the bow so water got in and soaked the deck foam. Most of the deck foam was detached from its fiberglass skins. I separated the deck from the hull and removed the inside skin and all the foam. Now I have to redo that sandwich panel. I could use Core Cell foam and that's probably what I will use but it's pretty expansive. Balsa is a little cheaper but its heavier. Nida core is light and less expansive.

Here's my question: Has someone ever repaired a deck with less expansive alternative material with good proven result and if so what material?

I have search the forum and found few threads on core material but nothing less expansive and with proven result.

Thanks for your help.
 
The OEM core is Airex, don't know the density. There are less expansive foam cores available.
Take a look at http://www.corecomposites.com/fileadmin/user_upload/documents/CoreComparisonChart.pdf for example.. But make sure you are getting a closed cell foam, and that it's compatible with the resin you are going to use..

Most Laser owners don't do a full core replacement, so I don't think you'll get a lot of answers here, but you might want to check other cored boat forums (Hobie Cats are one that come to mind, IIRC I read a number of threads there discussing core replacements and choices used)



If you are not concerned with class legality: Something to consider, you don't have to re-core it, you could go with a single skin laminate with glass ribs. It will be lighter, and less worry about the core/glass bond on the original deck, and substantial cost savings. Even a hybrid, cored in some areas, and single skin/ribs in others would save you a significant amount of money.
 
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49208,

I looked at that possibilities but the outer skin is so thin that it would flex even with minimum spaces between the ribs. Maybe a hybrid like you proposed. A thin foam sandwich backedup by ribs. I'll have to think about that further.

That will probably end up with the original method with corecell foam. I will take the opportunity to reinforce some area like around the topand the bottom of the mast well. Also I'll replace the plywood fdor screwing by some plastic.

Thanks for your comments.

AB
 
Hi 49208,
I remember, there was an instruction how to do such repair, somewhere at the former drLaser.org.
Perhaps you, or the TLF-staff-team, could search for it (WayBackMachine)? Or is that instruction 'too old'?
All I know, dr Laser is well and still is beating the waves successfully on his LaserRadial at the Marmara Sea (I did quit Facebook on Dec 31th 2013 in reason of the NSA/GCHQ-stink at GER, so, till then, unfortunately I lost contact with Shevy)

Rasmus may always give you an extra blow into your sail!

Lu
GER 203169
 
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