86 Smoker Craft Challenger floor replace

[Bow Guy]

going to price sheets of aluminum today.. I had a 1/8" 3'x3' piece in the basement and I laid it in the boat and stood on it and was good.. if the price is in the ballpark or even 100 bucks more the labor of using cost waterproofing is non existent.. just cut to fit and rivet it down.. and it i want glue some indoor outdoor carpet down and no rot ever again... I need 2 pieces 4' x 61" and 1 piece 17 1/2" x 60"

 

[Watermann]

I've heard people talk about using AL for decking but can't remember anyone ever doing it though.

I would consider marine vinyl rather than carpet, it would get you a whole bunch closer to no rot ever again. Carpet goes bad pretty quickly when you leave your boat to the elements because you're not worried about rot ever again.

 

[Bow Guy]

I made the plunge and bought the aluminum for the floor.. they cut it to the size i needed so I just have to fit it and cut the notch for the drain plug and bilge pump and the opening for the ski storage... and plenty left over for the dash and glove box side... and floor in the bow and then some.. 3 4x8 sheets cost me 367.00

 

[Watermann]

Looking forward to seeing the finished deck with the AL. Your smoker should also have side panels, are you going to use ply for them?

 

[Bow Guy]

yes..the starboard side is rotted where the controls mount so i have to replace that side but will do both and use the old ones for templates and reuse the vinyl covering, I will have to make them slightly deeper to make up the difference from the thickness of the 1/2 wood floor to the 1/8" new floor.. I might do the control panel in Al.. It may be a while but I will post pictures when I get the floor fitted and if the weather permits it....

 

[Bow Guy]

No Title

Aluminum all measured and ready to cut...

The picture of my archery shop on the floor the red blue yellow and green locking 2'x2' squares are what I am going to use over the aluminum floor so I can remove whenever I want and clean and dry and remove for winter storage... anti slip and comfy to stand and no gluing and inexpensive and come in gray.. I can cover the entire floof for 35 bucks...
Picture of my power plant...1974 650 Merc... was only used 4 summers sparingly and put in storage

 

[Bow Guy]

No Title

Started fitting the floor... notch is cut for Drain plug and Bilge pump... next ski well...

 

[Watermann]

Are you planning on using shims to get the consoles up to where they are supposed to be? Some words of advice, get the bilge pump installed and wired before you put the decking in for good. Was wondering what you're using to cut the AL with, that stuff is sin't the easiest to cut on. I found when using my cordless jigsaw on lengthy cuts is to spray WD40 on the line out ahead of the cut, it keeps the blade from turning into a butter knife.

 

[Bow Guy]

Are you planning on using shims to get the consoles up to where they are supposed to be? Some words of advice, get the bilge pump installed and wired before you put the decking in for good. Was wondering what you're using to cut the AL with, that stuff is sin't the easiest to cut on. I found when using my cordless jigsaw on lengthy cuts is to spray WD40 on the line out ahead of the cut, it keeps the blade from turning into a butter knife.

I just in the fitting stages of the floor right now... I had them cut the 2 main floor pieces where I bought the aluminum 61" x 48" ( they fit perfect) then I cut the well notch and Ski locker with a corded Jigsaw.. took a little longer than using a sawsall but can see the work better. I am stopping just under the console and will be using aluminum washers to shim the console,2 washers should do it... the small wood deck in the bow is very good and going to leave for now. The bilge pump is still installed and wired, I just have it lifted up out of the way for now. I'm not going to rivet anything down till I get everything fitted and the side panels made and fitted. I also want to make some kind of holder for the battery and fit the gas tank before reinstalling the sliding doors under the splash well.

 

[Bow Guy]

I have both the side panels cut and varnished and both dash boards cut and varnished. bought marine Vinyl at Joann Fabrics they had a 50% off sale and got 3 yards for 30.00.. Moved the boat into the garage yesterday and was able to pull the steering system, fuel gauge, and switch panel to restore and replace in new dash...Probably need to replace the switch panel.. one of the fuse caps won't lock in place and pops back out..

 

[Bow Guy]

No Title

side panels almost done just waiting on rivets both console dash boards next

 

[Bow Guy]

No Title

Port dashboard done...

 

[Bow Guy]

No Title

Helm Dash complete... Now to finish fitting the floor and install..

 

[Watermann]

Moving right along I see. :thumb:

What did you use the seal the wood for the panels?

 

[Bow Guy]

I used exterior plywood ( not PT) I sanded used Helmsman Spar Urethane sanded in between 3 coats after all the cutouts. after I got done I found Rustoleum Spar Varnish when I went back to lowes to get some black rustoleum for the helm mount,They keep it with the spray paint not with the stains and urethanes.. o well. they also carry Rustoleum Topside paint.. Good to know,

 

[Watermann]

Rusto Spar, I'll have to take a look next time I'm at HD, we don't have a Lowes here.

 

[Bow Guy]

No Title

Rusto Spar, I'll have to take a look next time I'm at HD, we don't have a Lowes here.

Installed 1/2" pvc to run wires to port console and bow area lights. First section of aluminum floor riveted in..

 

[Bow Guy]

No Title

Aluminum floor riveted in place...next to install ski locker frame and support brackets... Looks like i'm going to do the transom as a preventive measure and be done with it... don't want to take the motor off again once I have installed.. Can see much of the wood in the transom because it is encased in aluminum. Hopefully it will come out in in piece.. Any hints??

 

[Woodonglass]

Wow, I'm going to be interested in how hot that aluminum floor gets in the direct sunlight in the spring and summer fishing. Even with a good vinyl covering it's still gunna generate some heat I'd think. Keep us updated. I remember one member several years ago that purchased a large aluminum Interstate road sign from a salvage yard and used it for his deck and then glued foam backed carpet over it. Never did hear how it worked out for him. At least you'll never have to worry about rot!!!!

 

[Watermann]

Looking good and real shiny.

I would pull the splashwell out first off, end caps, transom cap, drain tubes and then decide which method you want to use to get the gunnels off the ends of the transom so it can be lifted out.