Subject: Deck softness
Date: Mon, 11 Sep 2017

Hello,

We have a soft spot on our deck. This is a 2008 Hunter 41DS, which we bought new in July, 2008. Several people think that the spot is a delimitation issue and does not have water inside. A moisture meter does not show anything. We had the windlass switches rebed last year.

Topside, the soft areas are all in the grey non-skid, running from around the switches back a few inches past the stanchion. The deck flexes from the top and from underneath. The soft spot dimensions, as tested by a hammer or screwdriver tap, are about 6 to 3 inches wide, by five or six feet in length. The non-skid slopes from centerline out to the hull about an inch or less on the grey area, and about two inches from switches to past stanchion.

Below, in the forward head, and cabin, we have exposed the underside of the entire area. The is no evidence of water, either now or previously. The area looks new, with no stains, or discoloration. Tapping the areas shows the same dead spots as topside. The underside has some flex as well, but doesn't seem to flex quite as much as the top.

Our questions are:
Two repair people think the topside deck is delaminating from the blocks under, as well as within it's top layers.
Would your CPES solidify the area? Would it need the regular epoxy after?
How can we tell whether it is the topside layer that is the problem?
Can this be repaired from below? This would avoid any color or non-skid matching issues.
We guess that a 3/32 drilled hole will accommodate the 14ga needle?
Can you inject from underneath, without everything running back out?

Dan L

CPES is not appropriate for this repair. It is too thin and does not fill voids. It is formulated to penetrate a porous substrate, such as wood, concrete, etc., and to act as a rot-preventive coating for all wood. What you need is to flood the affected area(s) with a slow-setting, non-shattering epoxy, such as our Layup & Laminating Resin. This can be pumped in from underneath through 1/4" drilled holes with our 10 oz Re-usable Caulking Tubes. The resin can be pumped in and then the hole quickly sealed with 2" clear packing tape. The L&L Resin can also be made into a soft slurry by adding some of our fine sawdust.

Doc

Date: Tue, 19 Sep 2017

Hey Doc,

Repairs complete, and deck is tight. A few spots, 2-3" diameter remain when sounded, but deck is firm.

I have the sawdust and a 2QT of L&L kit untouched. Please send me RMA or what ever you use.

Full report soon.

Thanks,
Daniel

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