Forepeak Repairs

Here's another post on boat projects. This time it's both forepeaks (i.e. the interior part of a vessel that is furthest forward) or as Alex likes to call it, the munchkin quarters. 

Last month, Alex finally repaired the crack in the starboard forward bulkhead, reinforced the floorboard in the starboard forepeak with fiberglass, and covered it with PVC foam board for a smooth finish that is both waterproof & easy to clean.

Alex in the starboard forepeak - sanding and vacuuming the area, prepping it to be reinforced (not a comfortable area to work in, as it necessitates crawling through the access port into a very narrow, raw fiberglass area, that has no air circulation). Did you notice the crack? ;)

Applied fiberglass & epoxy on existing floorboard

Topped it with PVC foam board

He also replaced the entire floorboard on the port side with fiberglass laminated plywood (& PVC foam board on top), as we discovered that the ply was too weak to reinforce - at one point we had some water leak into the forepeak without our knowledge, and it sat on the ply for several months. This eventually weakened the ply & made it buckle somewhat.

This is the damaged floorboard removed from the port side

We bought a piece of plywood, cut it to shape and reinforced it with fiberglass prior to fitting it back in the port forepeak.

Alex spreading the epoxy on the fiberglass with a metal roller

The floorboard was made out of 2 pieces to allow it to fit through the access port. This is obviously the bow section...

And this is the back part. Here's how we reinforced the plywood with fiberglass:
First, we applied a layer of epoxy on the "underside" of the plywood with a brush

Then, we placed the pre-cut fiberglass on the plywood and applied another layer of epoxy

Next, we spread the epoxy with a metal roller and set this aside to dry. Once dry, the fiberglass is sanded smooth

From top left to bottom right: The rotted floorboard removed from the port forepeak, the reinforced plywood sections, with fiberglass on the underside, are glued with epoxy & screwed into place, then another layer of fiberglass & epoxy is applied on the top side, and covered with the pre-cut PVC foam board (while the epoxy is still wet of course)

Finally a spinout is glued in with Sikaflex. This is what both forepeaks look like now

We also decided to make two new inspection ports to replace the old ones (which were made of plywood that we felt was a little too thin to be part of a bulkhead).

Found a piece of thicker plywood

Alex cuts the inner hole with a jig-saw while I help to hold it in place

The jig-saw is a really useful tool. So much faster and neater than trying to do it manually. Thanks Rene for lending it to us!

Next, Alex sanded it and applied 2 coats of epoxy to protect the wood

Sticking a strip of foam around the edges for a better seal

Placing a new spin-out on the inspection port

That's all for now. We have yet to paint the two inspection ports. Will update and post photos of that when we're done.

When you're a catamaran, you have two of everything. Sure, double the space and comfort but also double the cost and repairs!

Thanks for following our boat projects! ;-)