Aft berth kick board damaged by water leaking through the wood. all bottom side was soft and rotten

How it looked

Removed all bottom shelves from the battery area RH, and the LH lazarettes, then unscrewed all shelves and headboard in the berth. The kick boards are attached with screws in the bottom towards the stern, and at the top of the board towards the bow. They are also fiberglassed at the bottom aft side, but water damage made them easy to remove.

Remove old kick board

After removing all boards cleaned fiberglass angle where boards where attached, and drilled a 1 hole for draining the area into the bilge at red arrow.

LH side

The following pictures are from the area behind the battery switch. Any water leaks in this area will get into the kick board thru the liner foam.
The liner is installed before the deck. You can see the foam between the deck and hull.

Battery switch area

problem area

You can see the liner foam, tucked in, and ready to be sealed with 5200. The left hand side was in the same condition

Battery shelf corner

the kick board water damage stained the fiberglass. Water would run down in this area.

Rh side

Sealed with 5200. Left hand side was sealed in the same way.

Sealed

While repairing the leaks, I cleaned and inspected the water tank, found a couple of corrosion pitted areas on the bottom, thought of replacing the bottom of the tank but after looking inside the tank.... got a new plastic one from Dura-weld. Some newer 40.5 have a plastic tank made by Dura-cast, but they no longer have the molding, and recomended Dura cast. Triple M could also make the tank, but they wanted me to ship the old tank. The price tag from both were very close. $690.00

Aluminium Water Tank

Looks like barnacles grew inside. I have replaced the Oring at the fills and keep a constant check on them.

tank bottom from inside

Tank inside at supply (upside down)

new and old tank

new and old tank

1 hole drilled at arrow for draining

fitting new tank

Some newer 40.5 have a vertical board in this area, as well as at the fuel tank. Screws hold this tabs to the fiberglass floor

Tank attachment on side

The main attach of the tank was a strap around the tank and thru 2 holes in the floor.

New tank in place

Hunter used a 1/2 marine plywood with laminate, I used a 1/2 teak faced (both faces) marine plywood at about $200.00 a 8x4 sheet. Used cetol medium finish.

New kick board

I used 5200 where the board was fiberglassed before, and 4200 to seal around the edges after installing the boards in place.

attaching board

Re install the shelves and headboard

The finish product.....After
1 day to remove,
1 day to clean up and seal
1 day to check and reseal
4 days to cut trim wood
2 days to reassemble...

some days longer than others....

The view the Admiral likes