Do the other 4 guys that have same problem, are their boats around the same year as yours...2001?

Plexus is a structural adhesive that according to ITW "dissolves a thin layer of each mating surface and actually fuse two composite surfaces into one, creating a chemically cross-linked bond so strong that the composites will delaminate before the bond fails."
My first thought when i was reading Norts posting was that maybe Formula didnt clean the amine blush off the fiberglass parts after they cured and before they were put together. Then looking at that picture of the Formula worker puting the Plexus on the gel part of the hull and i think whats probably happening is the Plexus IS bonding but only to the Gel...and that is not structualy bonded to the glass uner it.....so it just sheers off in the high stress areas.

One is older (2000), and I think the rest are newer. Each is a different year. I think Dave Davis' boat is an '05 or '06?

I experienced a somewhat similar problem with our Larson in that there was a structural problem that they did not initially want to deal with. In the start the boat was perfect, but after the first year we noticed there were small spider cracks on the bow extending all the way down from the bow eye to the water line, and they kept expanding. Called Larson up, and after a couple discussions back and forth, being blown off numerous times, finally decided that they would cover it under warranty to get them fixed at a local marina.

Fast forward two years, and the exact same problem came back but much worse. Called the factory, and the first person we spoke to completely blew us off telling us it was our fault and we were misusing the boat. Complete BS. Called again, spoke with another person who we sent pictures to and after discussing the problem with the engineers, they decided that is was not misuse, but in fact a structural problem. So in the end they have made good, they came and picked up the boat after our season was done, and it is in the factory right now getting a complete new hull put on our deck.

Larson maned up on this one. So I would say, keep at it, for us it really did depend on who we spoke with, it took a couple calls to get to someone who did not completely blow us off. I would also seriously recommend actually calling the factory and speaking with someone. It is much easier to send a email reply blowing you off then it is when you can state your point and refute what they are saying.

Good luck

Interesting. I prefer to actually document the dialog with letters. Formula seems to want this too even though they emailed the letters, the original also came in the postal snail mail.

Here is my second letter to them.

I completely agree, I would much rather have emails with dates, and everything in hard copy by far. I just found that they were more willing to try to come to some understanding when you can have a direct back and forth dialogue without necessarily giving them time to think about a response via email. However, it really did take quite a few phone calls to get to someone who would actually work with me instead of just blowing me off, I got passed along to quite a few voicemails before actually getting someone who was willing to respond, let alone even help.

what junk plexus is on a little 16 Donzi, with 42 hours on it, yes, 42, complete seperation everywhere..boat is completely apart for repairs... it didn't bond anywhere, to anything.. my pic's are too large to attach

I am sad to read about this and really hope that this will be resolved to your satisfaction.

If I were you I would want Formula to fix this at the factory. They know the boat in detail and I believe they know how to fix this so it will last.

I think Formula should fix it free of charge and you should pay the transportation. I have no idea of the transportation cost (I am from Europe) but do realise you are far away from the factory. But for me it is all about getting the repair done properly so the boat will be OK again.

My real concern remains that others need to be made aware so they can monitor it.



Second letter from Formula.

Shoot them over to me and i will resize and post them up for ya :D
my work email: wwojcik@ marchpump.com