Cal 20 Discussion Forums

After sailing this weekend I've come to the sad realization that I need to replace my entire deck core.  It has become spongy in critical areas and time has finally taken its toll on the poor boat.  So does anyone have any tips for doing this on a Cal 20?  Such as method, material, etc.?

My current plan is to have her pulled out of the water early in the fall, take down the mast, remove all topside gear (winches and stuff) and then strip the interior plywood.  Let the underlying fiberglass air out for several days and then put the new deck core in place and then put everything back to the way it was.

Any thoughts and tips about this appreciated.

i have one of the older cal's with no deck core and just solid fiberglass...which are less likely to get spongy.... but if I were you (as long as the deck holds its shape with no weight on it) i would forget the new core and just remove the old and clean down to bare glass, then laminate it with several layers of fiberglass and heavy cloth, even alternating between chop strand and cloth on the inside...kind of a bust job because it's upside down, but it will give you a better long term result. ..at probably the same cost. On top of that you can just fair it a bit and paint it with a thick primer to conceal the booboos. If you are worried about the structural integrity, you could laminate stringers on the ceiling as well....your boat is probably 40 years old, so it would be good to make a fix that lasts for another 40....

Hi ChrisB,

Nope, I haven't started this project yet.  As usual another project being delayed.  Looks like early spring at this point unless we get a warm spell here in Maryland.  Any tips and advice would be greatly appreciated!

Steve