I've been working over the winter removing the wet balsa core from under two 27" wide pilot house windows (per side). Windows leaked for 25 years into the vertical 20" of 1/2" end grained balsa core below it. I needed a difficult project to occupy me. I chose not to remove the inner skin for several reasons.
Now I need to figure out how to insert a core into the 1/2" wide by about 28" wide, going down about 20". This 26' boat pilot house has no structural load above like a flying bridge. Just my weight erecting the winter cover. Inserting 7/16' solid Divinycel core will be tricky and blind. Reading some web materials, some offer pourable materials. Some say special foams would work (about 4 to 8 lbs/CF). But even if it was not the rapid expanding type, I would think once it started to expand and slowed the vertical expansion, it would have to expand sideways. Thick strong 3/16" outer gelcoat laminate. Weak 1/8" inner skin. Even if I tried to brace the inner skin, the expansion forces might overcome the bracing.
Any experience out there on this?
Thanks
Now I need to figure out how to insert a core into the 1/2" wide by about 28" wide, going down about 20". This 26' boat pilot house has no structural load above like a flying bridge. Just my weight erecting the winter cover. Inserting 7/16' solid Divinycel core will be tricky and blind. Reading some web materials, some offer pourable materials. Some say special foams would work (about 4 to 8 lbs/CF). But even if it was not the rapid expanding type, I would think once it started to expand and slowed the vertical expansion, it would have to expand sideways. Thick strong 3/16" outer gelcoat laminate. Weak 1/8" inner skin. Even if I tried to brace the inner skin, the expansion forces might overcome the bracing.
Any experience out there on this?
Thanks