More repairs....I'm about at my breaking point!

[BlewByYou88]

Now I'm questioning Sea Rays quality and engineering..... 268's Beware! I noticed this last season that there was a slight divot in my bow about half way down that extends from one side of the Bow to the other. Everytime someone walked across this point, it would bow terribly. Well, it started showing stress cracks in the gelcoat, so now I'm worried about the glass... Just a weak spot or???? Well, as luck would have it, it would appear that the soft spot is directly over the cross beam in the cabin where the curtains attatch. Strange right? I would have thought that would be a strong point since there are wooden cross beams glassed in under the deck....CAN YOU GUESS WHAT SEA RAY DID?

I pulled down the headliner and everything looked fine....I relaized the deck had a Balsa Wood core....ok so the only way to find out more would be to bust out the first layer of glass on the underside of the deck, and chop out the balsa...or go through the top and tear up gelcaot and non skid....I decided on going in from underneath the deck.

So, I thought, might as well bust out the cross members first, as I will probably have to put up new wood and re-glass anyway. Upon busting out the cross members, I found Sea Rays Fatal flaw in the Bow, and what caused the soft spot. There was no coring or second layer of glass under the cross members....in fact the glass is thin...scary thin...I can push with one finger and barley any pressure and make the deck flex up and down....

Attached are the pics of my reign of frustration on the bottom side of the deck....I don't have the pics of the low spots on the bow.

I cut out a 1.5' section the whole way across the underside of the deck. My plan is to take a piece of Oak or Maple and coat it with resin, and use a jack to push it securly up into the deck structure. This should make it far stronger in this area and act as a more stable filler than the Balsa Core. Then reglass all exposed areas with some Woven glass for the second layer. I will keep you guys posted as I progress.

If you guys see anythign strange or have better ideas...please feel free to chime in!


DSCN1265.jpg
DSCN1260.jpg
DSCN1261.jpg
DSCN1262.JPG

[sdarc]

Sorry to hear about this, If you use oak, use white oak instead of red. White is not porous red is.

And Bruswick obtained both Sea Ray and Bayliner in 1986... Hmmm!

[Henry Boyd]

I understand your being upset, but it is a 24 year old boat. Call me crazy, but it seems to me that a problem that takes 24 years to surface is hardly an engineering flaw.

I think using oak might be too stiff and create its own set of problems. Oak also has a tendency to warp at the slightest bit of moisture. Using marine plywood instead would provide the strength.

Henry

[KC_Sundancer]

I understand your being upset, but it is a 24 year old boat. Call me crazy, but it seems to me that a problem that takes 24 years to surface is hardly an engineering flaw.

Henry

Definitely an engineering flaw and weak point right from the start. A clear line for the deck to be able to "fold" along.
+1 on the marine grade plywood - more stable.

[alwhite00]

Man, I know it might not be right but if that's the worst of it - After nearly a quarter of a century I would say they still built a pretty nice boat.

LK

[BlewByYou88]

Bear in mind getlemen, shes a 24 yo boat that on a good day looks like she just floated in off the line. This boat hasn't had any abuse or neglect in that area...Shes always been under cover and shes a trailer queen...Its a clear flaw, you don't put an 1/8" of Glass over a high traffic area without ample support from underneath.

[Pyrojodge]

Geese, Stace good luck buddy. I agree on the marine lumber rather then a solid piece of wood. The engineered wood will not "move" like a solid piece. Good luck with the repair. Just think you will have a brand new boat that is engineered better then when it came off the line when you are finished!

PS: I am also jealous you're still able to boat!

[CV-23]

He's just gearing up for those pole dance girls on the bow! Just kidding......maybe?.....Mike.

[Buckeye Boater]

Stace,

Do you think the damage may be the result of all those young ladies dancing on the bow during the bachelor party last month? Good thing they didn't fall through the deck!!! By the way, we're still waiting on those pictures!!

[OldSkool]

Got to admire a guy who works resin and fiberglass overhead. Sounds like she will be in better shape than new. Go with the plywood as a more stable material. Keep the pictures coming so we can see your progress.
Best of luck.