How to Repair the Deck of a Bayliner Boat

The fiberglass deck of a Bayliner is covered with carpet. This adds an extra set of steps to an otherwise straightforward fiberglass repair project. Bayliner's carpet is proprietary, so the carpeting project is a repair, not replacement. Once the whole project is completed, you may find that you can't spot the place where you made either repair -- and that's the goal.

Things You'll Need

  • Razor utility knife
  • Drill
  • 1/4-inch bit
  • Marine epoxy kit
  • Poultry injector
  • Marine adhesive caulk
  • Paint roller
  • Disk grinder
  • Coarse sanding disk
  • Putty knife
  • Fiberglass mat
  • Fiberglass cloth
  • 80-grit sandpaper
  • Palm sander
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Instructions

  1. Damage Inspection

    • 1

      Step on the deck to locate the part that needs repair by how it feels underfoot.

    • 2

      Cut a three-sided flap of carpet above the damage using a razor knife, so that the longest side of the flap is nearest the center of the deck.

    • 3

      Inspect the damage to determine if the deck is broken or cracked, or if the fiberglass has delaminated -- lifted away from the core material of the boat.

    Delamination Damage Control

    • 4

      Push on the weakened area of fiberglass -- a soft feel to the fiberglass indicates that the layers of the fiberglass laminate have separated from the core. Avoid bursting any blister-like bubbles you may find.

    • 5

      Inspect the bottom of the carpet flap for water stains. Carefully inspect the surface of the fiberglass for breaks that might allow water to get into or through the fiberglass.

    • 6

      Drill 12 holes, each 1/4 inch in diameter, all the way through the fiberglass and the core with a drill and a 1/4-inch bit. Allow the area to dry for at least 72 hours.

    • 7

      Mix up the resin and hardener from a marine epoxy kit, in batches just large enough to fill a poultry injector, or about an ounce at a time. Use four drops of hardener for each ounce of resin, and as soon as the epoxy is mixed, pour it into the injector.

    • 8

      Insert the injector into one of the holes in the fiberglass under the delaminated edge and inject the epoxy. Continue to mix epoxy in small batches, refilling the injector as often as necessary to fill the soft area with epoxy. Allow the epoxy to cure for 24 hours.

    • 9

      Apply a thin layer of adhesive marine caulk to both the bottom of the carpet flap and the deck where the carpet will lie. Lay the flap into place and press down on its entire surface with a paint roller. Allow the adhesive caulk to set for 24 hours.

    Cracked Fiberglass

    • 10

      Grind a shallow depression around the cracked area, using a disk grinder and a coarse sanding disk.

    • 11

      Mix marine epoxy and apply it to the area with a putty knife. Follow the epoxy with a sheet of fiberglass mat. Follow the mat with more epoxy, working the mat down into the epoxy beneath it.

    • 12

      Lay a sheet of fiberglass cloth on top of the second layer of epoxy and work it into the epoxy. Repeat this process, with four layers of epoxy and fiberglass at a time. Allow the epoxy to cure between every four layers to avoid problems with delamination.

    • 13

      Continue to add layers of epoxy and fiberglass until the fiberglass patch at the center of the repair is level with the rest of the deck. Sand the fiberglass patch with 80-grit sandpaper and a palm sander until the entire patch is level with the deck.

    • 14

      Apply a thin layer of adhesive marine caulk to both the bottom of the carpet flap and the deck where the carpet will lie. Lay the flap into place and press down on its entire surface with a paint roller. Allow the adhesive caulk to set for 24 hours.