Mast step Backing Plate repair

[Mercrewser]

I have a boat that has been out in the elements for years without a mast step.  The plywood underneath has been compromised and under close inspection is wet and somewhat soft.  I think I better replace the wood under the maststep as per Craig's advice.  Problem is, I'm not that familiar with working with fiberglass.  Local shops are backed up over a month.  I think I might be able to handle this but I was hoping you might be able to answer some questions.
1,  Where is the best place to cut?  I assume a cutting wheel is to be used, but where?
2,  Sould I replace with pressure treated wood?
3,  How do I reinstall?  I was thinking that I have to coat the wood with resin, and then sandwich it back together again.  I'm not sure if I need new fiberglass cloth or not.
4,  I'll then fill the holes redrill and install the step.
I guess I can paint over the repair or re gelcoat.
Let me know what else as I dont want to have issues with this in the middle of the bay!!  Also, should I treat deep gouges in the keel with resin first before I regelcoat?  I want to do these repairs right as I take pride in having a nice boat.  Thanks!

[B.Hart]

fun with fiberglass :shock:    a cutting wheel will work ok, just dont cut through the deck :lol: then as you said resin coat the new wood but most important grind all the area to ensure a true bond. the glass will not bond to the old resin without grinding. good luck and keep us advised on progress happy sailing

[dgholmes]

I would offer another suggestion that would prevent you from cutting the wood out.  West Systems has a fix for that on their website.  They suggest drilling the holes larger to get to good material.  Let it dry out a bit if it is wet.  Then follow their directions.

www.westsystem.com

Then go to Boat Repair & restoration tab.  Then select "Repairing machined holes in fiberglass."  You can even download the pdf file to your computer.  The repair kits with low and high density filler can be found at West Marine.

This is what I am going to do to mine this week.  I will let you know how it goes.  I have used the West Systems stuff before to fill holes and it works great.

If you still think you need to replace your wood, this site has an article on that also.

They have a manual for $3 that is an excellent book for these types of repairs.  You can buy it on their website -- "Fiberglass Boat Repair and Mainenance."

Worth a try before doing it the hard way by cutting out the wood and replacing it.

[Mercrewser]

Just read your post, and I already ordered rot doctor materials.  They are probably very similar to west marine.  I dont have time to cut out wood, however I would if it was really soft.  thanks for your info and I too will post my results.

[Mercrewser]

Wood was in surprisingly good condition.  I drilled a bunch of holes thru the fiberglass to expose the wood.  I also cut some strips out near the mast step holes.  After waiting a week with an airmover blowing directly on it, I decided enough was enough and started using the rot doctor system on it.  The wood was still 20 percent wet according to my moisture meter, but I figured close enough.  Rot Doctor seems to be working well.  I will paint after repair.

[dgholmes]

I am glad you posted.  I forgot that I said I would do the same.  My problem was that someone had stripped out the tabernacle screws and moved the tabernacle back 1", drilled and remounted it.  This left open screw holes and the tabernacle NOT in the factory position.  

As mentioned,  I used the West System fiberglass repair kit.  I drilled out all 8 holes to about 1/4".  I checked the wood and it was in good shape.  I then followed the West Systems directions mixing the epoxy with the high density filler and filled all eight holes using the supplied syringe.  I didnt completely fill the holes leaving a little room for gelcoat.  

After the fiberglass repair was dry, I then applied the Evercoat color match gelcoat.  I then placed the tabernacle in its original location, marked, drilled four mounting holes and remounted the tabernacle in the factory location.  It worked perfectly.  The epoxy with the high density filler made a perfect base for the screws.

If you have never used the West Systems fiberglass repair kit, I highly recommend it.  They make a very quality product and the kit comes with everything you need including rubber gloves.

[Mercrewser]

I did buy the evercoat repair kit.  I got prepared to fix some of the gelcoat nicks on my boat yesterday.  But when I opened up the kit, it was missing the 4 0unces of repair paste.  Back to West Marine I go.