hidden problems, HELP!

[thedink9]

Hi Salvagefirst

I have a '85 23' in what appears to be the same layout and went through some of the work you have in front of you, over the past year. For the stringers, I found a number of voids where the foam must have been poured too quickly. I found you could actually sound them out with a rubber hammer. Drill access holes above these points near the top of the stringer, at least 1" in diameter. I would also drill drain holes along the entire bottom edge of the wet stringer. I used a couple portable fans aimed at the top holes and eventually over a few weeks, dried up the foam. Then patch the lower holes as Big Shrimpin described and pour new foam (SLOWLY) into all of the access holes on top. I actually used a complete one quart kit on my stringers, that were supposed to be filled at the factory. Once cured, patch the top holes and you onto the Fuel deck . There are many threads on the site on fuel deck replacement. I found that bedding a 3/4" epoxy coated piece of marine ply, into a strip of fiberglass putty, along both edges worked for me. The putty is available in a gallon size from Mertons supply, and has many other uses in the repair process as well. I covered the top and tabbed up the sides about 6 incles, with a 6oz mat and a layer or two of 1808 biax cloth. Hopefully bulletproof hereafter. I built a rear edge onto the deck, as well. Regarding attaching your tank to the deck, I also used 1/4" strips w/ 5200 to attach but I didn't foam the tank back in. Instead, I layed a small strip ( 1/2 x 1") of foamcore between the tank and the stringer on both sides. These strips take up any of the spacing in which the tank could move side to side. Between the 5200 strips on the bottom, the rear edge and these foam strips I do not believe the tank is going anywhere. I bought the tank from SP tanks in NJ, which I believe may be close to you. They offer for a small additional price to exopy coat the tank, which I would recommned. One word of caution. Make your final tank measurements (especially the height measurement) after the tank deck is glassed in. remember you'll be adding 1/4 " strips under the tank and a layer or two of glass to the top deck, so take that into consideration. Good luck and keep the pictures coming. Dink