Delamination of Core Material
Delamination is a common deck and hull construction problem which tends to get worse if left unattended. Eventually, the delamination can reach a point where the overall structural integrity of the hull and deck may be compromised.
Solution 3 -
Repairing cored deck, hull and bulkhead delamination
1. Define the delaminated area. Typically, exerting pressure on the skin yields a soft feel before contact with the core and indicates a gap between the skin and core.
2. Thoroughly drying the core must be accomplished before re-bonding. Drill 6mm holes, 25mm apart and about 75mm beyond the delamination area. Drill through the skin and about 1/3 of the way into the core.
Use a moderate source such as a hot air gun or heat lamp to accelerate the drying process. Take care not to damage the skin with excessive heat. A sample drilling from the core will indicate the degree of dryness.
3. Combine the epoxy mixture with 413 Microfibre Blend to ketchup consistency. Load a syringe. Trim the syringe tip as necessary.
4. Inject the thickened mixture into all holes drilled in the area. Flex the skin several times to work the epoxy into all areas between the skin and core.
5. When the mixture has coated the entire surface area between the skin and core, weights or pressure should be placed on the skin to force it into contact with the core until the epoxy cures. Placing a plastic sheet between the skin's surface and the weights will prevent inadvertent bonding.
6. After the epoxy is completely cured, sand the surface fair with 80-grit sandpaper. Any remaining low spots may be filled with epoxy and 411 Microsphere Blend mixed to a "mayonnaise" consistency. Sand when cured and coat with unthickened epoxy.
7. When cured, wet sand with 220-grit paper. Follow the paint manufacturer's recommendation for final preparation and application.