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I think the reason both of my decks had failed was 1) due to poor maintenance by the PO, and, 2) none of the holes made during manufacturing were ever epoxied or sealed. They just drilled through and called it a day.

I wasn't able to track down a single root cause after ripping everything apart and cleaning the boat.

Once I finish the project up this week, I'm going to be drilling the holes from the top, tape them, flip the decks over, overbore the holes from the underside and refill them with epoxy. Then I'm going to flip it back over and re-drill after the epoxy cures. This way I can be sure that all of the holes are water tight and that the plywood is physically separated from the holes. Then I'll seal the holes and perimeter of the decks with 4000. It sounds like a lot of work, but it shouldn't be more than an hour to do the job.