Removing rotten moldy plywood and vinyl headliner from cabin ceiling

White Shadow

Active Member
Feb 17, 2023
127
Vancouver, BC
Boat Info
320 Sundancer 2005
AB Dinghy w/9.9 Merc
Axiom 9 MFD
Kohler Model 5E Generator
Engines
Twin Mercury 350 MPI Horizons w/Bravo III Drives
I just posted this in the 320 Forum but thought I'd post it here as well in the hopes of getting more exposure and hopefully advice.

I had noticed a couple of drips coming from the starboard round ceiling porthole window on my 2005 320 DA. When I pulled the molding around the window I discovered that this must have been leaking for years as I found a lot of mold and rotted plywood. I have a number of pictures but am only attaching this one to give a general idea (and I didn't want to gross anyone out with some of the others). This is actually taken after I had scraped out all the mold and sprayed it down with a mold killer. The strange thing is we only ever saw maybe 2 drips, and never found water on the floor or anything. It must have just been pooling up there for ages.

So now I'm looking at removing and replacing the plywood in the ceiling (along with the vinyl headliner and anything else even remotely close by that may have mold on it (we don't like mold). I had a repair guy by yesterday looking at this with me and he is putting together an estimate. He has advised that it will be a range since a lot of it will depend on what we find when we get the headliner off. He said it's not horrible overall, but that depending on how Sea Ray had put this all together this will effect how much we have to take out, and what needs replaced (for example, is the headliner all one piece, or was it joined. Also how the plywood panels were installed, etc.). He is going to contact Sea Ray to see if they have diagrams outlining how this was all assembled. He is also going to ask about the source for the vinyl.

Have any of you ever had the pleasure of pulling the headliner and/or having to replace any of the plywood in the ceiling? I'd be very grateful for any advice on what is involved in this and what order to remove things in. Also if anyone has replaced the vinyl where did you get it from?

On a side note, I did also reseal the window from above. A bit late though...

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