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Gunwale Core Replacement for 1986 Hunter 23

posted 10-07-2008 by Mark Major

When the deck is raised from the hull adequately one will see at the highest point of the hull structure a space between the inner hull and outer hull where it flares outward to match the deck lip. Within this gap there is wood measuring 4” long, 1-1/2” wide, ½” thick placed end to end from stem to stern. I call this area a gunwale, for it runs the length of the boat, not including the stern area.

On my boat I found 60% of this wood rotten. I suspect it is typical of this year and model.

Rotten core material partially removed

Made from 3/8 rod with chisel end ground.

Removal tool

This wood was installed during manufacture when the fiberglass resin was still wet, therefore is adhered slightly. Drive a sharp putty knife between the surface of the wood and glass, loosening it. Pry wood from core area. For removal of subsequent pieces I fashioned a tool from a 3/8” rod that resembles a “bail hook”, flattened and sharpened with a chisel edge on the hook end. I found that leaving the wood half inserted assisted in keeping the hull edge exposed for easier removal of subsequent pieces.

Removal tool

After removing all pieces I took a 3” wire wheel and brushed out the core surfaces, as well as the inside edge of the deck lip (to remove caulk).

Use compressed air to blow out all debris.

Brush out remaining material

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