FRP / Plywood Deck Repair on a Rosborough 28

Our club race committee boat is a FRP Rosborough 28 which I believe was initially used for lobster fishing in Nova Scotia up until about 1990 when we converted it for use by our club. Over time the aft deck sole which is comprised of plywood sheeting with a fiberglass laminate outer layer has deteriorated due to moisture intrusion from the elements and as a result has weakened considerably to the point where we deemed it unsafe and a repair was necessary.

To that end after the boat was hauled for winter storage last fall we began by shrink wraping the entire boat leaving enough head room to allow for an adequate working space above the aft deck. We also installed a hindged plywood door for easy access. This past week myself and a couple of  other members, Mark Backman  and Bart Bies began the repair and re-construction of the deck sole.

The first step was to remove the FRP laminate layers from the rotted plywood. To do this we utilized a curcular saw with the blade depth set at approxametly 3/16″ and cut through the laminate layers in the required areas.

FRP saw

Cutting through the FRP layer to separate it from the plywood

After the cuts were made the next step was to searate the FRP outer skin from the rotted plywood panels. For this we untilzed a variety of wrecking an bars and a hammer. Actually due to the deteriorated condition of the plywod that FRP skin came off rather easily. The rotted plywood was removed as well.

FRP removal from plywood

Removing the FRP from the plywood.

The plan is to re-used the existing FRP skin over the new plywood after a re-build of the structural components.

frp and plywood deck

After removal of the bad stuff and a thorough clean up this is what we had.

So far this represents about 5 hours of work and the next step will be a re-construct of the transverse sole suports.

More to come.