DIY Boat Refit in Wrangell: Marine Plywood Demo, Stick Weld, Grind & Prep

In this nitty-gritty shipyard work session on the S/V Alaskan Gypsy, we carefully demo marine-plywood panels to get at spray-foam insulation that must be removed to avoid toxic smoke and fire hazards before welding. We walk through tool choices (a new Milwaukee brushless oscillating tool), safe foam removal to avoid fire during exterior welding, a low-heat 3/32" 6011 stick test (Miller Maxstar 160 S), mapping measurements from outside to inside, and a realistic grind/finish (Milwaukee 9' Grinder) strategy after building up the chine seam to repair electrolysis damage. Filmed on location in the shipyards in Wrangell, Alaska. What you’ll see: • Why we had to pull plywood to expose foam before welding (fire-safety) • Locating the exact weld zone from outside (browning the paint as a marker) • Dealing with hidden screws/putty, broken fasteners, and a bilge hose obstacle • 6011 rod choices (3/32" then 1/8") for controlled heat + build-up • Honest talk on “good enough” vs. perfection when there’s broader hull pitting • A quick grind to knock down high spots before epoxy paint later Gear & materials mentioned: marine plywood (3/8"), oscillating multi-tool (Milwaukee Fuel), 6011 electrodes, 9' grinder. Location: Wrangell, Alaska. If you’re into steel boat life, weld repairs, and liveaboard refits, hit subscribe and follow our Alaskan Gypsy Life playlist for the full rebuild story. Chapters (paste into description) 00:00 Why demo the plywood & foam (fire-safe weld prep) 00:43 Oscillating tool + shop setup 01:12 More demo to remove blocking & expose foam 02:07 Hidden screws under paint/putty 02:58 Foam out & electrolysis at the chine 03:57 Exposing the chine for weld access 04:36 Outside view: locating weld under the portlight 05:23 Test weld with 3/32" 6011 rod 06:14 Measuring the weld path (9" x ~3" area) 07:33 Inside check: browned paint marker + hose obstacle 08:35 Reality check + “build back better” quip 09:27 Multi-pass weld summary (then 1/8" 6011) 11:24 Quick grind: knock down the highs 12:26 On to the next section