One of the areas that I look at very carefully when surveying a boat is the integrity of the deck, especially if this contains some core material. There are a ton of good reasons for installing core material, it gives thickness to the deck, provides a measure of sound and thermal insulation and additionally adds stiffness. There are a variety of materials used for cores but far and away the most popular is balsa. Light in weight easy to work and relatively inexpensive it would appear to be the perfect material - until it gets wet. Once water finds its way in the balsa soaks up moisture quickly and if left unchecked rot soon follows which in time can migrate through large areas.
Keeping the balsa cores dry starts at the manufacturing stage and that means that reasonable steps must be taken by the builder to keep water on the outside. Bolts, screws, hatches and anything that penetrates the deck must have a hole that is properly sealed against the ingress of moisture, keeping the water out. Depending on the nature of the deck penetration the methods employed are varied. Where stanchion bases are located for instance the correct approach is to have a solid built up laminate without a core but sadly this is not always done. A solid base makes for a sturdy, safe handrail, the tension on the bolts can't crush a soft core and fractures and failures are minimized.
Even when a builder does the construction of the boat correctly they have no control over later additions undertaken by owners or third party boat yards, alterations which often are the cause of problems. I've often times seen holes drilled through a deck with no sealant, exposed cores and backing plates or washers on the inside that are either too small or non existent. This all sounds like gloom and doom but doing the job properly is not rocket science and will ensure your boat stays sound and dry. I will be bring you a step-by-step guide in the next day or two on the correct way to install deck hardware but in the meantime I wanted to share a couple of photos with you.
Excuse by shoes in the photo but this boat is about 5 years old, comes from a well respected builder yet had serious water problems with some of the balsa core all the result of an improperly completed vessel. Water had been allowed to get in by creeping past some wood trim had puddled down into the corners of the pilot house roof, a few winters of freeze thaw cycles and the die was cast. The repair yard had to open up areas by cutting off the exterior laminate, scoop out the rotten core then after allowing it to dry, install new core before finally making good the outer laminations, filling, fairing and last but not least spraying on new non skid.
This is the side of the wheelhouse which was also saturated necessitating the scooping out of the core to a depth of about 12 inches, the red light is the glow of heat lamp used to dry out the remaining moisture before the balsa is replaced. The cause of this malady was a teak capping with incomplete bedding that was set onto a non sealed edge, this was just asking for trouble. incidentally the capping was screwed on by driving 4 inch wood screws into the balsa. Not only did this fail to hold the trim in place the screws provided a conduit for the water to wick further down into the core material. All this could have been avoided, along with a hefty repair bill had a few simple precautions been taken when the boat was built.
More on core materials in a future posting.
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