Installing Hardware
Planning for high-stress deck hardware
With DuFLEX panels it is advisable to remove the balsa or foam core and replace with solid timber inserts ( plywood or cedar), in preparation for deck hardware bonding, fitting rudder tubes and windows. This distributes high, single-point loads over a larger area. The core should be routed out without damaging the inside laminate and the ply should be bonded in place and laminated with the same thickness and weight as the original panel, and faired in.
When holes are drilled in the timber core for bolts or screws they should be overdrilled and filled with epoxy and redrilled for the fastener after the resin has cured. This allows the epoxy to seal and protect the core exposed by the fastener hole. Fasteners should always be coated in resin before fitting. Additional information on hardware bonding and composite panels is available from ATL Composites.
Deck hatches
Make a pattern from the cut out information supplied by the hatch manufacturer, and cut the shape in the DuFLEX panel. Rout out the core and back fill the edges in the usual manner. Mark the location of the fasteners and then position the hatch. Silicone the edges to seal against water ingress.
For flat parts that need to be fitted to curved surfaces, such as hatches to the side of hulls, you will need to make a pattern, draw it onto the hull and cut the inside shape out. Make up a temporary jig and clamp over the hole on the outside. Backfill with a mixture of WEST SYSTEM resin/hardener and 411 Microsphere Blend to make it fit flush. Fair and mold in prior to attaching the part.
If you are planning your boat or catamaran construction then please do contact us, we will be more than happy to be of assistance.
