Fibreglassing a large area - Update

[Dunaruna]

I've just bought my first project boat, a 40ft houseboat. <br /><br />The sundeck (2nd story) needs a new floor, the old glass & gelcoat is weather beaten to death (some minor leaking inside). The roof area is 12ft x 30ft.<br />Its completely flat. The structure underneath the roof is steel frame with half inch marine ply sheets. The substructure is in very good condition with no visible cracks/holes or gaps of any sort. The new fibreglass floor will be used for lounging /BBQing and of course to weather seal the ground floor.<br /><br />I'm a hands on type of guy but I know nothing about glassing. If I take on this project I will probably need someone to initally 'hold my hand' so to speak.<br /><br /> Some houseboat roofs I've looked at are paint over fibreglass - no gelcoat, is this acceptable?<br /><br />Can the job be done successfully in sections (maybe 10ft x 10ft)?<br /><br />Is this type of job beyond the average DIY person?<br /><br />If I do this will you guys guide me? <br /><br />Thanks in advance.<br /><br />Aldo

 

[Boomyal]

Re: Fibreglassing a large area - Update

Whew! I feel for ya Dunaruna. I'll be interested in seeing the input. I'm close to glassing in my new floor (6' x 12') and I was concerned about that size.<br /><br />Congrats on your new toy!

 

[Dunaruna]

Re: Fibreglassing a large area - Update

I want to post pics but the boat is currently in a shed and I can't get full shots yet (can't get the whole boat in frame). Plenty of houseboat owners on the lake have given me advise but I suspect they are more interested in cost saving rather than quality. <br /><br />This is definetly a lifestyle investment but I got butterflys, sometimes I think I've bitten off more than I can chew.<br /><br />Aldo

 

[Boomyal]

Re: Fibreglassing a large area - Update

Are you going to be able to glass it in the shed?<br />You will definitely need some big squeegies and rollers. Hopefully you can pick a time when it is cool out and use slow curing resin. Maybe you'll be able to do the whole length of the boat in four foot strips, starting at the outside edges and working toward the center. Two overlapping longitudenal strips an each side and one top cap down the center.<br /><br />Hope you don't mind me doing a little musing here. I aren't no expert for sure. It would be cheaper to use polyester resin but I'm not sure if they make different cure rates like epoxy. Another thing to think about is UV protection. That might be what got the existing roof.<br /><br />A supplier would be able to advise on cloth weight and large scale tool availability.<br /><br />Ok, I'm done.<br /><br />Next expert please!

 

[Dunaruna]

Re: Fibreglassing a large area - Update

Muse away, I can use every little bit of info at this point. <br /><br />Yes I can use the shed and all it tools/equipment but at a cost.<br /><br />We are coming into our spring season now, cool evenings and hot days - mor importantly, lots of rain. Keeping the boat in the shed is a point of negotiation at the moment, the owner of the shed wants $200 per week, I would like it to stay there until the roof is sealed but I also want it on the water ASAP. The wet marina berth is paid for until July 2005. If I float the boat into the berth immediately I run the risk of damaging the exposed roof.<br /><br />The owner of the marina explained the process like this: Fill minor imperfections and rough sand, apply resin (roller), apply glass sheet, roll out air bubbles, repeat process after resin cures (total of 3 layers of glass). Apply thin resin coat & paint or gel coat. <br /><br />I think 10 x 10 is a managable working area, the overlap you talked about makes sense but I would need to be careful as not to produce a lump in the surface.<br /><br />I'll need to contact some suppliers and get ideas on what type of material/resin to use, you mentioned polyester, what other types are there and what are the differences?<br /><br />Its worth noting that the finished job will have no structural quality. From the information I have from locals the old roof lasted about 20 years, and it was an ex-rental boat so it would be fair to assume that the roof was regularly used and abused. <br /><br />Aldo

 

[Winger Ed.]

Re: Fibreglassing a large area - Update

All house boats are is survivors of a flooded trailer park.<br /><br /><br />Here's a idea for ya---<br /><br />Strip the deck of everything you can scrape off and toss over the side with a floor/tile scraper.<br /><br />Get some of that trailer house/mobile home roofing 'gooey'. The good stuff is about $50 (American) for 5 gallons. The cheap stuff is around $15 for 5 gallons(American) but is stays sticky for about a year. <br /><br />..<br /><br /><br />Once the deck is clean, dump the roofing 'gooey' out, and spread it with a mop you'll throw away when you're done. <br /><br />For what you're doing, 4 five gallon buckets should be plenty. Done right, it should seal the water leaks, and provide a good adhesive for your floor covering if you choose carpet,,,, especially if you can tack down the edges.<br /><br /><br />Before the stuff dries, roll down that indoor-outdoor carpet that looks like grass. Tack down the edges, or tuck it under the trim for the top deck.<br /><br /><br />With one or two 'mates' you should be finished and ready for the wheather before your next dock payment is due.

 

[Boomyal]

Re: Fibreglassing a large area - Update

I dunno, dunaruna. I hate to dispute as accomplished a craftsman as WingerEd. Undoubtedly his method is the cheapest and easiest but I don't think carpet would hold up well in the Aussie sun and with a flat roof, if you do get rain it will just hold it in. Plus his method may be best suited for a roof that will see no traffic.<br /><br />Without seeing the condition of the current roof, it's hard to comment on prep ideas but I would get on the telly first, thing Monday, and check out resin options then eventual final covering for UV protection. May be a two part catalytic white floor paint like used on concrete. White is a must. That floor would get killer hot, if not. The paint could be put on once the boat is in it's slip. <br /><br />I'm not convinced that so many layers would be nececcary either. If the roof structure is sound, with out a lot of flex, I think one fairly heavy layer, over the patched existing layer, would suffice after proper surface prep. You do want to consider the existing fiberglass covering. If it was Epoxy resin, apparently the polyester will not adhere. The other way around is A-ok.<br /><br />In the US, polyester resin, as opposed to Epoxy resin is a about a quarter of the cost. I would rely on the FG expert, however, to tell you which would be suitable.<br /><br />With a friend, you could probably lay it in three nights after prep. If the resin you use gives a long enough working time, I would do two full 40 foot outside rows on night 1 and 2, then the top cap, down the middle on night three.<br /><br />Funny, I was just getting ready to have to go thru this a few years ago before I had to sell my houseboat (10' x 30') due to a move. You can see a flap of the deteriorated vinyl roof covering hanging over the front edge of the roof. I was just a few months away from being an expert on this subject. Wish I was down there to help you. I could use some of that Australian sun with our cloudy fall/winter coming on. <br /><br />

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<br /><br />Tore my heart out, having to sell that boat.

 

[Dunaruna]

Re: Fibreglassing a large area - Update

I thought about the astro turf or carpet method but decided it would look to 'cheezy'. I'm not scared to spend some money to do it right, I just want to do it right the first time - don't want to have to revisit this project again. The old glass roof is gone (removed by previous owner), just bare substructure left and its in very good condition. Flex is zero, 6 mates running around and we could not detect any flexing - its rock solid. The first 3rd of the roof will be all solar panels so the usable area will be about 12ft x 20ft.<br /><br />

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<br /><br />I'll get a pic of the roof next weekend.<br /><br />Aldo

 

[Boomyal]

Re: Fibreglassing a large area - Update

Piece of cake, DR.(12 x 20) Like you say, do it right and you'll never have to do it again. Just remember, any final color, other than white, will burn your bare feet, now. My roof was light green vinyl and in the central California sun, it would blister your feet.<br /><br />If you do the fiberglass, I strongly advise you give the substrate a precoating of thinned resin otherwise your application for laying glass will get sucked into the plywood and give a very poor bond with the glass. You want to use a resin that does not blush, for the pre-coating.<br /><br />You got yourself an awesome retreat!

 

[Peter J Fraser]

Re: Fibreglassing a large area - Update

Hi Aldo,<br />Many years back I extended our deck at home out to about 36' x 15'. It has a fibreboard surface and we had problems with the joints failing 2-3 years later.<br />Solution: "RHINO" spray on utility bed liner. Perfect, no more leaks but is flexible enough to move with the sub surface. Still looks good 8 years later.<br /><br />Regards<br /><br />Peter

 

[Dunaruna]

Re: Fibreglassing a large area - Update

Peter, havn't heard of Rhino spray, I'll do some googling on the subject. Thanks for the input.<br /><br />Boomyal, 'retreat' is the perfect description in the warmer months for my wife and I. In the cooler months its the mothership for trout hunting. Can't wait!<br /><br />Aldo

 

[zzub]

Re: Fibreglassing a large area - Update

I would use fiberglas matt instead of cloth , you can do it in sections and blend it into itself, with a nice smooth transition 2 tin layers or one heavier wiehgt matt its flexable & water proof. Paint it with a textured Paint, Like you can use aroun swimming pool. Iv done this on a couple of boats.

 

[amidaeus]

Re: Fibreglassing a large area - Update

I just finished spraying my deck with Ultra-Tuff. It is easy on the bare feet and you can spray it in with a texture gun. It also comes in many colors. Check it out www.ultratuff.net

 

[Dunaruna]

Re: Fibreglassing a large area - Update

I've chickened out of doing the job myself. I could buy all the materials required for about $1200.00 plus a few weekends doing it myself. I found a trademan who specialises in houseboat roofs and he quoted me $2000.00 (2 layers glass & flowcoat) all up with a ten year warranty. Thanks for all the input guys.<br /><br />Aldo

 

[Boomyal]

Re: Fibreglassing a large area - Update

Originally posted by Dunaruna:<br /> I've chickened out of doing the job myself. I could buy all the materials required for about $1200.00 plus a few weekends doing it myself. I found a trademan who specialises in houseboat roofs and he quoted me $2000.00 (2 layers glass & flowcoat) all up with a ten year warranty. Thanks for all the input guys.<br /><br />Aldo

Ya gonna watch and learn? Like to hear what you witness. Be good to hear the particulars of how they conducted the event and what kind of materials they used. Never know when it might come in handy for some of the posters.<br /><br />ps, what is flowcoat?

 

[lark2004]

Re: Fibreglassing a large area - Update

flow-coat is Gel-coat. Just what some Australians refer to it as.

 

[Dunaruna]

Re: Fibreglassing a large area - Update

Boomyal, I'm gunna watch and take pictures through the whole process because I'm interested in learning how its done (properly). I'll take notes on the exact materials used. <br /><br />I know nothing about this subject but it was explained to me that flowcoat is a type of gelcoat that 'flows' easier to achieve a perfect surface, finds its own level so to speak, ideal for flat areas. It can also accept fine grit (sand?) for a slightly rough and therfore anti-slip surface. <br /><br />Aldo

 

[Boomyal]

Re: Fibreglassing a large area - Update

Aw, heck, I was countin on comin down to help ya. Our sun is fading fast, up here in the cloudy Northwest.<br />What color are you having it done in? and yeah, picture will be great.

 

[Dunaruna]

Re: Fibreglassing a large area - Update

Big range of colors to chose from but I'm going with white and probably paint a edge trim in sky blue (currently negotiating with wifey). <br /><br />I was up at the lake all weekend sandblasting and painting the fuel tank. Got sunburnt sitting outside eating lunch, 28c and not a cloud in the sky. You welcome to come on down and watch me watch him .<br /><br />Aldo

 

[Boomyal]

Re: Fibreglassing a large area - Update

Originally posted by Dunaruna:<br /> ...probably paint a edge trim in sky blue (currently negotiating with wifey).

PINK, you say?<br /><br />I'll check with my travel agent after I get done puttin my 20 footer back together.