How to Repair a Chaparral Boat Deck

Chaparral boats, whether a basic bass boat or the larger saltwater deck boats, are carpeted with a low-pile, marine-grade carpet. This means there are advantages and disadvantages when repairing the deck. While the fiberglass deck doesn't require as much finish work, the carpet can retain water that subsequently infiltrated the deck, causing a soft, easily damaged spot in the deck. As part of the repair process, the carpet must be dried.

Things You'll Need

  • Phillips screwdriver
  • Plastic hammer
  • Putty knife
  • Razor knife
  • Acetone
  • Cloth
  • Rotary grinder
  • 36-grit sandpaper
  • 6-ounce fiberglass cloth
  • Fiberglass repair kit
  • Clean plastic cup
  • Plastic utensil
  • Plastic spreader
  • Palm sander
  • 80-grit sandpaper
  • Wet-dry vacuum cleaner
  • Marine carpet adhesive
  • Safety glasses
  • Gloves
  • Long-sleeve shirt
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Instructions

    • 1

      Remove the screws from the trim strips that hold the carpet in place over the part of the cockpit deck where damage is suspected by using a Phillips screwdriver. Pull the carpet back to expose the damage.

    • 2

      Remove any broken fiberglass from the deck. Tap the area around the damage with a plastic hammer, listening for a dull thud that indicates de-laminated fiberglass you must remove. Scrape any carpet adhesive from the area by using a putty knife and a razor knife. Wipe the area with acetone on a cloth to remove any remaining grease, water or adhesive.

    • 3

      Grind down the center of the damaged area with a rotary grinder and 36-grit sandpaper, taking care to not penetrate the fiberglass, until removing as much damaged fiberglass as possible. Begin to grind around the damage, starting at the center and grinding shallower with each pass. Ideally, the area you grind will be 12 times as wide as it is deep, forming a shallow pit with the damage at the center.

    • 4

      Cut circular fiberglass patches from 6-ounce fiberglass cloth. The first patch should be as large as the damage. Each subsequent patch should be about 1 inch larger in diameter. Make the last patch as large as the area you ground away. Note that for each 1/4 inch of the depth of the damage, you will need four layers of fiberglass and epoxy.

    • 5

      Mix the resin and hardener of a fiberglass repair kit, following the manufacturer's guidelines for mixing. Mix the epoxy thoroughly in a clean, plastic cup in small -- about 1 ounce -- batches by using a plastic utensil. Spread the epoxy into the damaged area with a plastic spreader. Press the smallest layer of fiberglass cloth into the epoxy. Slather another layer of epoxy over the fiberglass cloth. Press the next-largest layer of fiberglass cloth into the epoxy. Repeat this process, four layers at a time, and allow the epoxy to cure completely between each four layers of fiberglass.

    • 6

      Sand the final layer of fiberglass by using a palm sander and 80-grit sandpaper until smooth. The repair doesn't need to be pretty, but it must be even with the surrounding deck area. The carpet in Chaparral boats shows uneven areas in the deck readily. Vacuum the sanding dust by using a wet-dry vacuum cleaner and wipe up any remaining dust with acetone and a cloth. Allow the acetone to evaporate.

    • 7

      Apply marine carpet adhesive to the deck. Pull the carpet over the repair and press it into place. Position the trim strips that hold the edge of the carpet in place. Thread the trim screws through the trim strip and tighten them securely.