Here's the Story of my pain (exgerated) and pictures to boot :)
The original endgrain Balsa core had been long since rotted and in desprated need of replacement, both sides where identical as far as how much had gone soft and degree.
Previous Owners had left me with presents on both sides, it's apparent the tried a recore, but in-lieu-of core they used epoxy . . . straight epoxy, my guess about 1 gallon of it, grind grind grind . . .
Grind, scrape, sand, sweep, ahh that looks good, ready for core . . .
Core? yes I did replace endgrain balsa with endgrain balsa, people who have been in the bussiness for longer then I have been alive had a strong argument that it is good stuff . . . oh and it was free :)
A belt sander worked great to level and shave the balsa core.
I chose the vacuum bag, for greater pressure imparted on the core, both sides were bagged, I can't stress enough that all edges and exposed existing core, as well as any holes made in the underskin, must be sealed, or the pump wont keep up with the leaks.
Post bagging and I had begun filling the gaps in the core, The gaps were left intentionally, my logic was that if a leak devloped and began migrating within the core, the "dam" between the core sections would mitgate the damage.
