2003 270 Soft Bow Deck Repair

JonnyMJonnyM Member Posts: 332 ✭✭✭
in Rinker Express Cruisers Forum
I have begun replacement of the rotted coring of my bow deck on my 2003 270.  I have gained some knowledge from this forum and YouTube and think I am on the right track.  I cut out all of the underlayers of fiberglass and removed all the rotted coring.  I have a couple fans in the boat making sure everything is dried out.  I plan to finish sanding the area this weekend and to start epoxying the new balsa core in place. 

Here are some pictures of the progress.  The white circles that look like mold are a product I used couple of years ago called "Inject a Deck."  It didn't work that well.

For those who have tackled this project, I welcome your tips, tricks, and advise.
"Mosi on Dahn"  2003 Fiesta Vee 270
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  • YYZRCYYZRC Member Posts: 5,416 ✭✭✭✭✭
    Huge project! 
    2006 390 EC
    2008 350 EC
    Georgian Bay
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    @YYZRC I will feel so much better when it is complete!
    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • captkevincaptkevin Member Posts: 553 ✭✭✭
    I can imagine.That looks like a fairly extensive project
    2004 232
    2021 Yamaha Fx svho
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    @captkevin It is for sure.  I just keep telling myself I am saving thousands.  The hard part is mostly done (I think.)  Cutting fiberglass with a Tyvek suit and a respirator on is not a good time.  The old coring scrapped off in mostly little pieces that I had to vacuum up while not sucking up the plastic or drop cloth.
    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • aero3113aero3113 Member Posts: 9,774 ✭✭✭✭✭
    Looks like you’re making good progress @JonnyM ! Soon you’ll be cruising! ⚓️
    2008 330EC
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  • captkevincaptkevin Member Posts: 553 ✭✭✭
    What is the plan for rebuild?
    2004 232
    2021 Yamaha Fx svho
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    @captkevin I am installing 3/4" balsa coring by epoxying it to the top deck, then a few layers of new fiberglass on the bottom.  Hope to have more pictures this weekend of progress.
    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    Update:

    I installed most of the wood coring.  Now I am almost ready to start laying glass over everything.

    Mixing the epoxy with silica filler helped to make the panels stick better when installing them overhead.  The harbor freight poles/jacks also helped to support the panels.


    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • YYZRCYYZRC Member Posts: 5,416 ✭✭✭✭✭
    You, sir, are fearless. 
    2006 390 EC
    2008 350 EC
    Georgian Bay
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    @YYZRC actually my anxiety was very high lol.  I feel better now, and I feel like I have turned the corner toward completion.

    Now if I could only get the epoxy out of my hair!
    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • captkevincaptkevin Member Posts: 553 ✭✭✭
    Very impressive. Was wondering how you would support the panels to adhere.
    2004 232
    2021 Yamaha Fx svho
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  • aero3113aero3113 Member Posts: 9,774 ✭✭✭✭✭
    Awesome, looks great! ⚓️
    2008 330EC
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  • rasburyrasbury Member Posts: 8,944 ✭✭✭✭✭
    Wow!
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    @captkevin As you can see in the pics, I had to get creative.  The wood X is from some kids game I found at our marina and the round thing supporting the other piece of wood is a electrical box support for a fan.
    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • Cableguy GregCableguy Greg Member Posts: 5,077 ✭✭✭✭✭
    You are doing a great job. A friend of mine has the same issue on his 270 and he couldn’t figure out how to support the coring. Last I heard he has all but given up. His boat is sitting in storage and hasn’t touched it in years. 
    2008 280 Express Cruiser, 6.2MPI, B3, Pittsburgh, PA "Blue Ayes" (Sold)
    2022 Cherokee 294GEBG Black Label land yacht. 
    Go Steelers!!!
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    @Cableguy Greg The hardest part was templating the pieces because I didn't cut straight.  Those support poles make it much easier too.  
    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • PickleRickPickleRick Member Posts: 4,341 ✭✭✭✭✭
    edited May 2025
    I've only seen this done on sailboats.  That's a huge undertaking....itchy too. 



    Personally, I would have cut from the outside then sprayed the top side area with properly tinted/thinned raptor liner from a gravity fed gun.  Not as rough of a finish as the bed liner spray gun they sell with the kit but still rough enough to cover imperfections where you would scab the patch back in place.   (I'm lazy)

    Your method is by far cleaner and much better for any future resale value.  

    Amazing work! 

    What's the plans for new headliner? 






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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    @PickleRick It has been a big project for sure.  The nice thing is I don't have to make it look that nice because it will be covered up.  The original headliner is in good condition and will be put back up when I am finished glassing.
    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    Here are some more pictures of the progress.  All the balsa coring is now installed.  I plan on starting to lay the fiberglass over it tomorrow.  It may be overboard but I am filling all the seams with Total Boat Total Fair fairing compound (green stuff.)


    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    After getting more epoxy in my hair and running out of resin twice, I am finally finished with the project.  I am very happy with the results.  The deck is now completely solid.  

    It was a pretty big undertaking but doable.


    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    1st layer of glass.

    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    2nd layer of glass.


    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    Headliner going back in.

    With new speakers too.


    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    New cabin lights.

    Obeaming 7.3 Inch 12 Volt LED... https://www.amazon.com/dp/B0991PZTH3?ref=ppx_pop_mob_ap_share


    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    New oceanair hatch screen.

    I
    "Mosi on Dahn"  2003 Fiesta Vee 270
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  • captkevincaptkevin Member Posts: 553 ✭✭✭
    Looks amazing, Congrats
    2004 232
    2021 Yamaha Fx svho
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  • TonyG13TonyG13 Member Posts: 1,438 ✭✭✭✭
    Awesome job! What's your guesstimate on hours and dollars to do the job?
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  • aero3113aero3113 Member Posts: 9,774 ✭✭✭✭✭
    Awesome!!
    Job well done!! ⚓️
    2008 330EC
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  • JonnyMJonnyM Member Posts: 332 ✭✭✭
    @TonyG13 Thanks.  I'd estimate around $1,000 to $1,500.  It took around 30-40 hours off and on evenings and weekends.  I'd assume it would have cost 8-10 grand if I would have taken it somewhere to do it if I could even find someone in this area.
    "Mosi on Dahn"  2003 Fiesta Vee 270
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