Overhead Panel Replacement

[Al in FL]

My Cal33-2 took some water through leaky port seals during last year’s hurricanes and was closed up with the dorade vent removed for a while. As a result of the high humidity the Masonite backing for the vinyl overhead panels in the main cabin softened and sagged.

I thought some thin plywood would be a better choice for the substrate, so I used the Masonite as patterns, cut new panels from what passes for ¼” plywood today, ordered some vinyl, but I am not having success gluing the vinyl to the plywood. I first used 3M Super 77 as recommended by a friend. I applied it strictly by the directions but the 1-1/2” to 2” tabs on the back side, and the front edges, which were originally tight and secure, released creating bubbles on the front edges and unglued tabs on the back.

After some internet research I contacted 3M who recommended their Rubber and Vinyl 80 adhesive and said I could overspray the old 77 adhesive. While the results are better, I still have some released areas. I’m beginning to believe the vinyl is the problem, perhaps the solvent in the adhesive is attacking the vinyl.

Has anyone replaced their overhead panels with any success and if so, what did you use?

Thanks,

Al

[Salty Tom]

Hi

C3775E6D-CE7F-4790-BAC2-D2CAF49F6663.jpeg (3.95 MiB) Viewed 2269 times

Al, we just redid our ceiling on a Cal 2-34. We used the old panels as patters to make news with a different configuration. We got a deal on some really nice Yellow Cedar screwed it up in panels with closed cell foam against the fibreglass. The yellow cedar was milled to about 3/8 x 2 1/2”. This was glued with PL Premium to door skin.
No more mould! Cleanable and refinishable. I think the same could be done with a birch ply.

[Noezway]

Great look!