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We found some rot in a 25 year old wall in our shower room on the boat.
The shower wall is 3/4in marine ply faced with laminate.
The approach we have taken so far is to cut out the rotten wood (there is a fibreglass pan/drawer box behind the lower part of the wall and a solid teak wall behind the upper part) until the wood around is good.
We made templates of the 3 sections (one is on the other wall to the bottom right, but that is the easy one) and then cut and sealed some marine ply to shape (18mm as couldn't find 3/4in).
It's been really hard to get these 2 sections to face off level with the existing wall.
If we don't use packing (thin sealed board) then it is recessed by a couple of mm
If we do use packing, then it's mostly level apart from the lower part near the floor angles out, and the upper part of the 2 joining sections is raised above the existing wall. So where that vertical join is is a bit wonky. The fibreglass pan at the back isn't 100% level which doesn't help things.
The goal is to get these 2 patches to sit flush with each other and the existing wall.
We have some 0.7mm cream/beige laminate we plan to stick over the top and half way up the wall to finish and plan to add a dark blue or dark grey vinyl stripe to better hide the join.
Get a really good clear sealant to go around the edges.
We have considered replacing the whole lower part of the wall, but it could take us into drilling through the teak on the other side which we are trying to avoid.
Most of this will be hidden by a folded shower screen except when the shower is in use.
As it's marine ply, it doesn't plane very well.
Are there any useful suggestions on how to resolve this?
Is it a good idea to connect the 2 new pieces together along that join so they are flush with each other?
We are thinking to use some kind of expanding filler behind (that sealant is going to be critical in ensuring water doesn't wick up).
Should we just use the sander to flatten it all out? (We have Random Orbital, a multitool sander and a belt sander available).
For sticking the laminate down we were thinking of using something like Evo Stick Contact Adhesive
For sealant - we are looking for something that will be strong and mould resistant that can be reapplied every few years.
Thanks in advance
