Discovering a soft spot on your boat deck is a frustrating moment for any owner. Often caused by moisture intrusion or improper factory sealing, these weak areas require prompt attention before they compromise the structural integrity of the vessel.

Fortunately, with the right materials and a bit of know-how, this common issue is completely fixable. Today, we are excited to feature a fantastic repair project from one of our talented Fiberglass Warehouse customers, Rick.

Rick recently tackled a challenging soft spot on his boat, caused by a manufacturing defect where the factory failed to seal the area correctly. Using top-quality composites and careful technique, he restored his boat floor to be stronger than ever.

Prepping the Coosa Board

Rick chose Coosa board as his core material, an excellent alternative to plywood because it will never rot. To ensure perfect alignment of the replacement panels, he used a biscuit cutter. He then glued the Coosa board pieces together using our high-strength vinyl ester structural putty.

Filling the Voids

Because the original factory seal had failed, several localized soft spots had developed in the surrounding area. Rick used the same vinyl ester structural putty to meticulously fill and fix all of these compromised spots, creating a solid foundation for the fiberglass layers.

Laying the Fiberglass

With the core pieced together and the voids filled, it was time to lock everything into place. Rick used a combination of Chopped Strand Mat (CSM), 1708 fiberglass cloth and vinyl ester resin to glue the Coosa board down securely, holding everything firmly with clamps while it cured. To ensure the bottom of the panel was completely waterproof, he applied two solid layers of CSM to seal it completely.

Final Installation

After the fiberglass work was fully cured and the new panel was complete, Rick placed the repaired section back into the boat. For the final touch, he sealed it securely in place using 3M 4200 white caulk, ensuring a watertight and flexible bond that will withstand the harsh marine environment.

Ready to tackle your own boat repair?

Rick's project is a perfect example of how the right composite materials can breathe new life into an aging or damaged boat. By replacing rot-prone materials with Coosa board and sealing it properly with vinyl ester putty, vinyl ester resin and high-quality fiberglass, he ensured his boat will stay on the water for years to come.

If you are dealing with a soft spot on your own deck, Fiberglass Warehouse has what you need to get the job done right. Check out our wide selection of fiberglass cloth, structural putties, and marine-grade resins to start your next repair project today.