A^4
Active member
I have done many projects on my boat over the years, but this one was pretty gnarly, came out great and might inspire some other insane person to do the same or similar thing. Basically my roof had some water damage from the previous owner moving the antennae around, and from putting screws that were too long in for the dome light. The screws went thru the top just enough to crack the gelcoat up top, I really never saw it until I felt water on my head while cruising out to Catalina 4 months ago. It probably leaked water for at least a few years when I bought it. As well, I want a belly loop on the roof, and could have just fixed that damage and put it up there, but I wanted to create a flat deck for a cooler seat on my curved roof, add a ton of strength for large people, and repair the water damage. It came out adjacent to perfect.
Cut out all the damage and created the space for the coosa board to insert later., you can see the staining where water damage was getting worse.
Adhesive filler layer to make it more uniform.
Chop matting fiberglass, some cloth, in many different size cuts to give it a flatter surface on this convex roof. I think it ended up being about 13 layers of glass on the outside, 3 down the middle.
Two more thick chop layers underneath to attach the coosa board. Note to anyone using coosa board, very light, very strong, very rigid, be careful with the sander!
Jackson Pollock
Tons of sanding, spot fiberglass jobs, and adhesive filler resin multiple times during the entire process in numerous spots, to get that final layer as level and smooth as possible. Final cloth layer.
Then some gelcoat, sand, prime, sand...
, non skid paint, cure, and put everything back together.
Now when I get the belly loop in 9 months, the seat will have plenty of support, and the roof will be a lot stronger.
Cut out all the damage and created the space for the coosa board to insert later., you can see the staining where water damage was getting worse.
Adhesive filler layer to make it more uniform.
Chop matting fiberglass, some cloth, in many different size cuts to give it a flatter surface on this convex roof. I think it ended up being about 13 layers of glass on the outside, 3 down the middle.
Two more thick chop layers underneath to attach the coosa board. Note to anyone using coosa board, very light, very strong, very rigid, be careful with the sander!
Jackson Pollock
Tons of sanding, spot fiberglass jobs, and adhesive filler resin multiple times during the entire process in numerous spots, to get that final layer as level and smooth as possible. Final cloth layer.
Then some gelcoat, sand, prime, sand...
, non skid paint, cure, and put everything back together.
Now when I get the belly loop in 9 months, the seat will have plenty of support, and the roof will be a lot stronger.
