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Subject: Deck core thickness
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Scott Waterhouse
Posts:53
08/08/2006 10:28 AM  
I am about to start fixing some damagaed core areas on my 1978 deck and wanted to get some materials on order before start. Does anyone know what thickness cores were used in the deck. I will be working near the mast/ along the main hatch and by the primary winch locations.
Hull #970 (1978)
No Sailing Yet - Still Rebuilding!
Rich Taylor
Posts:28
08/08/2006 1:56 PM  
I don't know if this is consistent for all boats (probably not), but here's what I found from chopping open and recoring a number of places on the deck of my boat:

1. The predominant core material for the deck is 1/2" balsa. This is used for most areas of curved deck and the majority of the flat deck. (exceptions below)
Brand name: Baltek Contourcore
Cheapest source I know is Jamestown Distributors @ $32.44 for a 2' x 4' sheet. Also available at Defender.com

2. 1/2" plywood under the stanchions, original winch locations (close to traveler) and in the small area between lazarette hatch and the stern.

3. 3/4" balsa core for about 16 inches of the flat deck - extending from the vertical cabin face towards the back of the boat. This ends up under the genoa tracks and typical forward primary winch locations.

4. 1" wide strip of 5/8" balsa between the 3/4" balsa and 1/2" balsa for the rest of the flat deck.

This is sorta hard to imagine. It may help to look at pictures of my recoring job at: http://www.imageevent.com/taylorpix/j24work.
On the starboard side I had rotten balsa starting under the genoa track, following the 5/8" core strip inboard and then spreading around the original and current winch positions.
Inside the boat I can see a stair-step for the 3/4" -> 5/8" -> 1/2" balsa transition - that may be a way to pre-determine what sizes of core you need.

I ended up recoring a very small area where 3/4" and 5/8" core was used, so I bought only 1/2" core and either built it up with fiberglass or sanded down 1/2" core to 1/4" thick to shim.

It can be a big job - good luck!

- Rich Taylor, #140 ('77)
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