Just to recap the progress so far:
1. Cut/chizeled/pulled/pryed out the old core.
2. Stiffened up the first thin layers that makes the surface or skin of deck by injecting resin directly into drilled holes.
3. Epoxied the area I put the 3/4" marine ply into for new core (and also put a layer on the side of the ply that went in). Drilled a few holes in the marine ply to let air escape and find its way out the top.
4. Used syringes to inject resin into the seems and around the sides of newly placed core. Found as many heavy things as possible, and put them all on the hatch to sandwich that thing good. It does make a difference, you could see air bubbles escape along the sides and through the holes of the marine ply.
After going back and forth on how thick to make the new core, I am happy with keeping it to 3/4". Only thing I may look into, is putting one more 3/4" peice the width of the stuffing box/tranny hatch/gas tank retaining walls so that the middle of the hatch will have extra support along those retaining walls once put into place. Contemplating the idea, I think leaving it as is would be just as fine too.
My friend had a good point, it was solid as rock even with a saturated core so anything better than what was in it is overkill now.
Plans moving forward:
1. Let the core cure really well.
2. Epoxy resin the topside of the marine plywood, and layer some 1708 mat on top of it. I have something very similar, actually heavier than 1708 I plan on using.
3. I will mix up some West System 403-410 as needed to fill the voids between the new core and the existing lip I left.
4. Sand her down, paint her up.
5. Move onto the other hatches.
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