Wooden Boat Restoration Repair - WEST SYSTEM Epoxy

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6. Clamp the plank in place with #10 sheet metal screws and large washers. Place the screws and washers between the strips, 8" apart. Each row of screws will clamp the edges of two adjoining planks and act as spacers (Figure 5-24 left). Coat the screws and washers with a mold release or place a small sheet of plastic under the washers to prevent bonding. Washers may also be cut from stiff plastic, thin wood lathe or similar stock with holes drilled for the screws. Tighten the screws down completely after pushing both adjoining strips tight against the screws. The epoxy mixture should squeeze up between the strips. Any voids between the planks should be filled at this time with the 655/graphite mixture. Fill holes and gap with G/flex 655/423 Graphite 1 8"– 1 4" THICK STRIPS (veneers) Repairing Hull and Deck Planking 42 1 4"– 3 4" THICK STRIPS (planks) Figure 5-24 Sheet metal screws with large washers will clamp the strips in position until the 655/graphite mixture cures thoroughly. 7. Place the remaining strips, several at time, following the same procedure. 8. Allow the epoxy to cure between 8 and 24 hours before removing the screws and washers. If you wait any longer than this, it will become much harder to break the screws free. Tighten the screw slightly (5°) before backing it out. If you have difficulty removing a screw, heat the head with a soldering gun’s cutter tip. While the screw is still hot, try to unscrew it again. Repeat until you are successful. 9. Fill the screw holes with 655/graphite mixture. A syringe loaded with the mixture will speed the process. 10. Sand the surface with a reciprocating sander and 50-grit sandpaper to level the epoxy and teak surfaces. Sand until the saw marks are removed from the teak surface. Fine sand with 80-grit sandpaper, and then finish with 120-grit. The teak surface may be left natural or finished with a marine-grade teak oil. Note: If planks thicker than ¼" are used, do not fill between the planks with thickened epoxy. Instead, remove squeezed-out epoxy between planks and allow to cure. Remove the screws and washers and sand the top surface of the planks fair. Fill the joints with Thiokol or polysulfide caulk (Figure 5-24 right). Wooden Boat Restoration & Repair ©2008 Gougeon Brothers Inc., All rights reserved. 5
6 Installing Hardware 6.1 Fastener bonding Now that the deck is upgraded, the hardware should receive the same thorough attention. To overcome problems associated with hardware installation on wooden boats, Gougeon Brothers, Inc. has developed an approach called hardware bonding. As the name implies, hardware items are bonded (glued) to wood with the goal of distributing high, single-point loads over as large an area of wood fiber as possible, while allowing the epoxy to seal and protect the wood end grain exposed by the fastener hole. Note: the term “hardware bonding” as used in this manual does not refer to the electrical bonding of hardware to eliminate stray current corrosion. There are two ways to do this. The first is to bond all fasteners (screws, bolts or threaded rod) directly to the surrounding wood fiber. The second is to bond both the fasteners and the hardware itself to the immediate wood fiber on which it rests. Using proper hardware bonding installation techniques, you can dramatically improve the load-carrying capacity of your hardware over that possible with standard hardware installation methods. In saltwater applications, our experience has been that bonded hardware and fasteners show excellent resistance to corrosion attack. Where fasteners are vulnerable to flexure and saltwater attack (e.g., hollow or bridged traveler tracks, bonded U-bolts or solitary eyebolts) a small silicone sealant fillet covering the joint between the cured epoxy and the fastener will protect against moisture and salt intrusion. Of course, any exposed metal surface will be subject to the effects of saltwater corrosion; therefore proper maintenance and cleaning procedures must be practiced. The fastener-to-wood bond can be done in several ways. The easiest and most common method is simply to wet out a standard-size pilot hole for a given fastener with resin/hardener. Make easy fastener bonds as follows: 1. Use a pipe cleaner or syringe to work the mixture well into the hole. 2. Insert the fastener in the hole and allow the epoxy to cure. This forms a wood/epoxy matrix around the fastener that is much stronger than the wood by itself, and distributes the fastener load over more of the wood fiber area. 6.2 Hardware bonding Installing Hardware 43 You can further improve the load-carrying capability of the hardware by increasing the amount of epoxy that surrounds the fastener (taking advantage of the fact that WEST SYSTEM ® epoxy has much higher density and strength than the wood fiber itself) and bonding the hardware base directly to the surface. Bond for increased load transfer as follows: 6
Page 1 and 2: 002-970 Wooden Boat Restoration & R
Page 3 and 4: TableofContents 1 Introduction 1.1
Page 5 and 6: 1 Introduction Introduction 1 Since
Page 7 and 8: You need to decide the level of rep
Page 9 and 10: Introduction 5 The many joints in a
Page 11 and 12: 1.4.3 Ventilating for longevity Int
Page 13 and 14: Figure 2-1 Typical structural frame
Page 15 and 16: ecause moisture can be trapped unde
Page 17 and 18: 3 Repairing Localized Dry Rot 3.1 E
Page 19 and 20: 3.2 Drilling and filling A common,
Page 21 and 22: Repairing the Structural Framework
Page 23 and 24: 5. Remove the frame from the jig af
Page 25 and 26: 2. Laminate a new piece slightly la
Page 27 and 28: 4.6.1 Repairing floors attend to. T
Page 29 and 30: Product tip—G/flex 655 Epoxy Adhe
Page 31 and 32: 5 Repairing Hull and Deck Planking
Page 33 and 34: 5.1.2 Filling the seams with wood A
Page 35 and 36: Figure 5-6 Replace a section of pla
Page 37 and 38: 2. Scrape the old paint and caulk o
Page 39 and 40: Place new layers ½" to either side
Page 41 and 42: 5. Clamp the sheet temporarily with
Page 43 and 44: 5 Bond the second layer of veneers
Page 45: 5.5 Installing a teak veneer deck R
Page 49 and 50: 6.3 Casting epoxy bases for hardwar
Page 51 and 52: 3. Wet out the lower end of the stu
Page 53 and 54: Figure 7-1 Effect of color on surfa
Page 55 and 56: Figure 7-3 Roll lightly and randoml
Page 57 and 58: Safety 7.4.1 Surface glazing 7.4.2
Page 59 and 60: 8 UsingWEST SYSTEM Epoxy 8.1 Epoxy
Page 61 and 62: 206 Slow Hardener ® —Used for ge
Page 63 and 64: 8.3 Handling epoxy This section exp
Page 65 and 66: 8.3.3 Dispensing and mixing stroke
Page 67 and 68: Additives Additives are used to giv
Page 69 and 70: Product tip—G/flex Epoxy is a tou
Page 71 and 72: 8.4.3 Bonding with fillets Vacuum b
Page 73 and 74: 8.4.5 Applying woven cloth and tape
Page 75 and 76: Using WEST SYSTEM Epoxy 71 Figure 8
Page 77 and 78: Problem solving guide Problem solvi
Page 79 and 80: Wood data Wood data 75 Wooden Boat
Page 81 and 82: Additional reading Additional readi
Page 83: Additional building and repair info

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