Found some pics from about a year ago of the front casting deck on My project. I had just yanked the carpet and was planning to prep for bed liner material when I found this and knew I had a new nightmare to deal with. Took two weeks but fixed her up right.



Finding out there was rot there, I started cutting a small area that got bigger and bigger until I saw about a quarter of the front part of the deck was rotton and the oly way to make it look right would be to cut all the way across so thats what I did. Then glassed and screwed in some cleats for the new deck wood to fit in on. Had to do some figuring on the cleats and used strips of fiberglass cloth to shim the cleats so that the new plywood would lay level.



Had some Plywood left from where I had made my floors out of that had a layer of 1 1/2 oz glass already resined in. Took the cut out and used like a stencil. Cut with a jig saw and then completely sealed all surfaces with resin. Layed in the cutout hole on the cleats and after a little edge work in a couple spots with the grinder, got a tight fit. after that, I checked with a straight edge for any dips. Had to cut out a few pieces of cloth to lay like a topo map to get it level. After this pic, I put two layers of 1 1/2 oz mat over the whole piece and now You can't even tell I did it. turned out great.



I had also put some fir 2X4 braces under the deck to strengthen it. You can dance on that thing now and it don't move.