Mark Petrush

Filling that pesky space between the underside of the deck and the top of the headliner. This is important, because if you don't, any epoxy that you pour into deck from above (to fill the void resulting from balsa core removal) will just run away into the space between the deck and headliner.

Each job is a little different, but what works for me is to get a dowel that will be a tight fit in the grabrail bolt hole in the deck. Insert this dowel from above so that it just slightly protrudes through the deck into that space between the headliner and the underside of the deck. (We're talking small fractions of an inch here.) You can usually see in there pretty well with a mini maglite if the batteries are good... you can also use a piece of stiff wire or a q-tip to gauge the distance between the deck and headliner and go from there.

Apply masking tape on the area of the headliner around the hole in question, punch out the hole and using a putty knife, pack thickened epoxy (peanut butter consistancy) into the hole from below. Keep track of the approximate amount that you are using, visualizing the volume required to fill the gap out around the hole and inch or so, then pack in a little extra for insurance and tape over the hole.

Watch the leftover batch of epoxy mix and when it starts to set up, go topside and remove the dowel. If for some reason the epoxy sets with the dowel still in place (admirers always stop by to gawk and talk where Tritons are concerned), you can cut it off flush with the deck and drill it out, but it's much easier to get it removed before the filler sets.

After this you can pour epoxy in from above to seal the core without it leaking into the interdeck void and running out the window gaps (don't ask how I know this) and proceed with the fix as outlined in in the West System book on boat repair. (the best three bucks any boat owner ever spent).

With the headliner backed up in this fashion, you will end up with a repair that is more solid and less prone to leaking, and the core material and headliner gap will be totally sealed off.