Deck Repair Options

Jbreamsiii

Jbreamsiii

Member
Sep 14, 2021
33
Louisville, KY
Boat Info
1996 Sea Ray 215 Express Cruiser
Engines
5.7L Mercuiser
We have a 96 215 Express Cruiser we bought last year that has some soft areas on the front deck around the hatch. Mostly on Starboard side and between the window and the hatch. The port side is fairly solid. I assume from leaking over time. Researching options and thinking of trying Injectadeck. Do you think by removing the hatch I can get to it from the side without having to drill holes on my deck and the non skid? What other options might be good? I am trying to do this on a budget, but want to do a good job on the repair. The boat otherwise is in excellent shape with low hours on the engine and runs like a champ.
 
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The only way to know is to remove the hatch and see what you have.
 
As we discussed in your other thread about this, the first step is to pull the hatch and see what you got. Everything else is just conjecture at this point.
 
Yes, will be pulling the hatch for sure. But having never taken it off I just wondered is it even an option to get at it from the side? Either way it needs to come out to be re-sealed so I’ll just look and see.
 
I spoke the the Injectadeck folks today. Nice people!!! Gave me a whole Tutorial on what to do and how to attack this issue from the side. I ordered the kit and will try to get this done when it arrives. I’ll see if I can do a write up and get a lot of pictures.
 
If you can get access from the edge with the hatch out, you may be able to dig out the rotted wood and insert a piece of epoxy soaked plywood into the space and clamp til dry. I've done this successfully more than once on various boats. If the soft spot is behind an area of solid wood, then edge injection would be a good option.
 
I hope I'm not hijacking this thread but it seems to be related, new here.
I recently bought a 2000 Searay 270 and shortly after found the entire deck from the Windshield to the Hatch and the full width of the top is very soft. Incredibly disappointing to say the least. I'm wondering if anyone has tried fixing an area this size through the Hatch and if so with Injectadeck or inserting long strips of wood with resin or something? If I should be asking elsewhere please let me know.
 
I just did my Injectadeck repair this past weekend. It seems pretty solid. I had the same issues from the windshield and hatch. Resealed the hatch with 4200. I still have to fix the windshield issue. The gentleman from Injectadeck suggested using Simpson Strong tie in the screw holes to seal them. You are going to have to drill. No way to get to it through the hatch really. And the foam needs a place to escape or it will bilge your deck or cabin roof possibly.
 

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From everything I've read it sounds like bulging could be a concern for sure. Was hoping to not have to drill though.
How many holes did you have to drill? Whereabouts were they and how did you repair them? Any pictures?
 
I drilled probably 25+ as it was my whole upper deck. Pic’s above. It turned out pretty well. The deck is super solid. They told me that stuff would find its way out and I had two spots where it came through the roof of cabin and leaked onto cushions. I forgot to cover area with plastic, but was able to get it off in time. I would definitely make sure you lay down plastic everywhere in your cabin!!! Lol

The one thing is the holes when I patched with the epoxy took on a brownish tint, I guess from the foam instead of being white. So I would look at buying the 1/4” or 1/2” plugs someone else mentioned. In the Spring I am going to work with one of the local fiberglass guys to resurface and re-apply the non skid to the deck. He said he’d teach me and it was super easy and I could use his shop (since I didn’t really have a place to work on it) and materials for $400 vs $1,400 if they did it. So I jumped on that!!!
Will update with final pics then.
 
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