As you already know and I can confirm with certainty, all things are connected. Long story short, last year, I decided to tackle the old bottom paint job on my little boat and found blisters. So, tackled that job, too. Then realized the interior must be dry as well, so sought out that musty, moldy smell in the cuddy cabin. Let's just say I now understand how the term "bilge water" could be a curse word in the days of old.
So, here's the unsuspecting interior view:
Started snooping:
Kept looking:
Found it. I had already sopped up sponge-fulls of water. No telling how long it had been in their. PO, right. ::) Water is one thing in there, but the three small plywood squares (one in the photo) where completely soaked. I have never seen plywood turn to sponge before. The foam looks like a two part polyurethane poured on place. The plywood squares, I assume, were set up in place to prevent the expansion from interfering with the compression post access area.
Cleaned up, a little. You can't see it well in the photo, but the compression post bolt holes are elongated. Probably not a good sign. Didn't photo the forward side if the small bulkhead, but there was evidence of water damage there as well. In fact, prior to cutting the hole in the floor around the compression post, I tested the bulkhead plywood with a screwdriver. It pushed in quite easily.
Here's the "half full" foam:
Now for my reconstruction. I removed the remaining floor that was glassed in, leaving a small edge of the tabbing as a guide. I removed the bulkhead and used it as a template for the new, also leaving a small amount of tabbing (1-2mm) as a guide. The original plywood was probably Class B-C grade with on layer of loose fitting fiberglass tabbing. I did take the opportunity to peer under the berths. All clear. No evidence of water in those nether regions. Foam was OK, too. However, I must confess, I did replace the plywood with the same grade B-C. This, of course, happened after I viewed all the posts regarding marine grade plywood. But, I rationalize, the pieces are stiff (read small) and dry with minimal voids. I attached these with fillets per the West System instructions and glassed over the fillets with 4" biaxial tape followed by 6" biaxial tape on either side of the bulkheads.
I added the forward bulkhead, because the floor came out in two pieces. It would not have gone through the companionway as one big piece. So, I figured I could replace it in two pieces with the added benefit of creating three airtight compartments. This may serve as flotation and provide more stiffness than the foam.
I tabbed and glassed the forward section of floor yesterday, but have no photos as I write this. Will post later. Any input is welcomed.
Paul
