Building a center cockpit deck. Advice needed Please.

[Jabula]

Due to poor interior space caused by an aft cockpit, I would like to build a center cockpit onto my flat deck C&C 40". Looking at it, it seems plausable and would allow me to put a double berth in the stern. I would like to build a male mould and glass over as opposed to a female mould. I just think as a one-off, a male would be a quicker and cheaper way to go? As the deck is balsa cored now, should I keep this balsa cored too? The concern I have is the laying up and final finnish - without a moulded gel coat. What would the best way be to fair the finnish and apply a gel coat or paint finnish. Also, a laying glass fibre 101 lesson would be appreciated. How many layers of mat and grade? I'm sure this may have been discussed in this forum before, but I can't seem to find it. Thanks in advance.

[jimslade]

Ply and glass and lots of grunt work. paint is the easy way unless your familiar with gel. 1/2 inch ply with 3 layers of 1810 glass and 1 layer of cloth for finish. fair with light weight filler and paint, two part urethane.

[Jabula]

Thanks Jimslade. Should I use marine ply? Is 1810 glass woven roven or ? Three layers on each side of the ply? Polyester resin ok? How do I get the rough texture finish as on the rest of the deck?

[Jabula]

Just an added question whilst here. When laying down cloth, I always have a problem trying to make it stick around corners no matter how much of an overlap I leave. How do I prevent lifting and causing bubbles?

[buckknekkid]

why not a foam sandwich

[jimslade]

I like dried out pressure treated wood. use 1810 stitch mat. it is 18 oz oriented glass with a 1 oz mat attached to it. dont use woven its old tech. one layer inside 3 outside gradually extending away. use a metal mat roller it will help in getting out the air bubbles.radius the corners with a puddy mixture of resin and cabosil. polyester is fine. there are kits to replace the textured surface. Foam will also work but I have found it takes more expir. to work with.

[Jabula]

Thank You jimslade,
Your advice is much appreciated. I see you're "just up the rood from me", can you recomened a supplier to me that may deliver to Halifax?