Fuel Tank Panel

[Towerboat1]

Removed the fuel tank panel from the floor of our 77 222 this evening. I found that it was spongy when you walked on it and the reason is that the plywood under the FG skin is bad. How have you guys handled this in the past. Is it as easy as resining a new piece of plywood and putting it back together or is the plywood supposed to be bonded to the panel? Thanks for your assistance! CR

[Marcq]

Never done it before but what I have read on the subject is, remove the the under skin, remove the rotten plywood to bare fiberglass ,prep it, replace with a new plywood piece, bond it to the panel with fiberglass or epoxy and reskin

I'm sure others will chime in

Marc..

[GoneFission]

Here's a link that might help:

http://classicaquasport.com/smf/index.php?topic=6907.msg50941#msg50941

Good luck!

[Towerboat1]

I guess thats about the best I could ask for in instructions! CR

[Bill]

There are folks on this board that are a lot more expert than me, who can tell you the best ways of taking care of the problem. But what I did worked well: I removed the hatch, flipped it over, and used Git Rot, an epoxy filler --- you drill holes in the bad areas, expanding out until you hit wood, then fill each hole -- the liquid runs throughout, where ever there is vacant space, before it hardens. There must be other brands, but that was what was on the shelf when I went looking.  My hatch was in bad shape and it tool a LOT of filler, but once all the bad areas were done, the hatch was much improved. Then, to be "sure," I cut a piece of fiber glass cloth to the size of the whole underside of the hatch and resin-ed it in place. Problem solved.

Good luck!

Bill
Shark Shadow

[Mad Dog]

CR,

I have a rebuild working at this time.  Most of the work is a complete rip out and replace but I have three hatches that are part of the original fordeck that I will have to re-core.  I know the core material has turned to compost so I need to get that out first.  I will work from the under side of the hatches.  Using a 4" angle grinder with a thin cut off blade I'll cut the glass loose that is covering the core material (probably balsa (crapp, IMHO)).  Peeling that layer of glass off.  Using a coarse (#20 to #40) grit disk I will clean off all the residue and smooth out the surface.

Next I'll cut 1/2" marine plywood to fit the hatch, being careful to leave the inset around the lip.  Sanding the plywood sheet to prep it for epoxy (no Bondo) resin, apply at least two coats of resin to both sides and all edges (we want this thing sealed completely).  Apply one coat of resin to the inside of the hatch. Mix a putty of woodflour and epoxy resin (enough to cover the area of contact).  Using a 1/4" notched spreader I'll coat the inside of the hatch then lay the fitted plywood core in place.  Do not clamp this tightly.  Just place some weights to hold pressure.  Any putty that oozes out use a plastic spoon and spread it along the edges to make a filet (like finishing a caulking job around a bath tube).  Give the wood putty several hours to set up.

Once the core material stuck good then apply a layer of biax cloth with epoxy resin. This give the underside of the plywood a little more protection from impact damage.  It does not hold the core in place the woodflour putty does that very well.

Once all the resin and putty are cured you are ready to go.  A little trick to protect your hard work is to drill a any holes twice the size that you need them then fill them back in with the wood flour putty.  Then redrill the correct size.  This way you are assured no water penetrates around the threads.

Good luck.