Floor Replacement Made Simple!

[BoatFun]

Hi Guys!
Ok It is getting that time again, YA!! And before the season starts I want to replace my floor (whole). So I have been looking around and researching how to go about it, but the thing is there is SO MUCH out there, but nothing seeming like nice SIMPLE details? (A lot of broken links also...)
So what I would like is if someone that knows the ins and out of putting in a floor could JUST give me the tools needed, not all the ?giving? power tools, but specifically What epoxy/resin and glass cloth to buy and how to apply it? Not which Epoxy is stronger and a bunch of different names, but just this ?type? of epoxy and maybe a brand name that is generally.
I know I am going to buy ? marine plywood? I know you can glass both sides etc?
But I just need the basics 123? (Steps) and I should be fine? (1. Screw wood down, 2. then apply resin on top of wood?. Very simple and basic...)
If someone could do this I am sure not only me but others would also appreciate it!!
If you guys do have a guide to this with pics you could also mention them, but I have seen many and like I said I really just want the BASICS?
Again so for like materials:
There is basically 3 components the bonding agent(s), glass cloth/Tape, and wood??? What brand ?type? do I buy??? And where and when do I use them, this is all I really need!!!
Sorry if I repeated a lot, I just would like to run in a store get everything on the grocery list and go to work!!!
THANK YOU!!! VEARY MUCH!!!!

 

[Bondo]

Re: Floor Replacement Made Simple!

but nothing seeming like nice SIMPLE details?

Ayuh,... Life is Never Simple,+ This is No different....

All the Answers you're looking for are Right here in this forum,....

 

[92excel]

Re: Floor Replacement Made Simple!

Perhaps purchasing "Runabout Renovation" written by Jim Anderson would be a good place to start.. It gives you the basics from finding a boat to finishing the renovation. Its the very basic How To that you are looking for

 

[mrmiddlemann26]

Re: Floor Replacement Made Simple!

I agree with you...i am in the same "boat". I have ripped up my floor...put down new marine grade flooring and now need to glass the rest in.

Need to know the brand to get the ball rolling and what i need to do.

if there answers are already here...can we get a link?

 

[Mark42]

Re: Floor Replacement Made Simple!

I agree with you...i am in the same "boat". I have ripped up my floor...put down new marine grade flooring and now need to glass the rest in.

Need to know the brand to get the ball rolling and what i need to do.

if there answers are already here...can we get a link?

http://forums.iboats.com/showthread.php?t=286013

 

[jonesg]

Re: Floor Replacement Made Simple!

Call US composites.com , they'll tell you what you need,
there's too many variables for nutshell answers.
Got unlimited funds? go with epoxy.

 

[erikgreen]

Re: Floor Replacement Made Simple!

Actually, just go with epoxy. You'll need to paint over it to protect it from the sun, but it'll be much safer for you doing a first time job to have the extra strength.

In a nutshell:

1) Buy US Composites epoxy (uscomposites.com), the thin "638" series, in the medium hardening variant

2) Buy a quart of glass microbubbles or phenolic bubbles as filler, from the same source

3) Buy enough 6 inch glass tape in 8.7 oz weight, same source, to cover the perimeter of your deck, and to go around the edges of any breaks in it... IE, if your new deck will be three pieces of wood, make sure you have enough tape to go around the edges of each one.

4) Buy enough 6 oz. woven glass from them to cover your entire deck with one layer. Each yard of glass is a linear three feet that's as wide as the listed size. So buying three yards of 55 inch glass will get you a piece 55 inches wide and 9 feet long.


So what you'll do is remove the old deck, clean out any water or wet foam you find, and clean the inside of the hull where the deck attached of any dirt, carpet, adhesive, or loose fiberglass, and sand it well, so you only have clean fiberglass showing. Then:

* cut your new plywood deck to size, using cardboard to make templates of the boat first, then using them to cut the plywood to size

* dry fit the deck pieces, making sure they clear all obstacles

* take out the new pieces and cover both sides with a thin layer of epoxy using a foam roller. Use a brush to make sure the edges are sealed too. Let it harden.

* screw or (preferably) glue the deck pieces down. You can use either epoxy with filler for this (buy some milled fibers or silica for this) or even easier use PL premium polyurethane adhesive from your local store.

* Clean the edges of the deck and the sides of the hull where the deck meets them with acetone or xylene. A bit of light sanding on each wouldn't hurt either.

* Using the epoxy and microbubble filler, run a fillet with at least a 3/8 inch radius around the edges of the deck, filling in any gaps between the deck and hull, providing a smooth transition between the vertical sides of the boat and the horizontal deck. If you used screws to hold the new deck down, this would be a good time to cover the heads where you counter sunk the screws with filler and smooth it flat.

* while the filler is still somewhat wet, use the tape to make a join between deck and hull around all the edges of the deck pieces. Use this method:

1) Pre-cut pieces of tape to fit the edges, making sure you don't have gaps or more than a small overlap between pieces.

1) Use a foam roller to apply a thin layer of epoxy where the glass will go, being careful not to mush the fillet you made

2) Place the dry tape where you want it on the wet epoxy. Adjust position as necessary, and fit it to the curve of the fillet so there are no folds or bubbles.

3) Use the foam roller with some more epoxy to wet out the cloth. Take your time and be aware the cloth won't wet out instantly. Give it a minute or two to absorb before you add more epoxy. When the cloth goes clear, it's wet out.

4) Let the whole thing harden for a couple of days, then sand down any sharp spots or runs. Clean with a cloth and xylene again.

* Paint the new deck, covering all the epoxy, or cover it with carpet or truck bedliner.

Enjoy.

 

[BoatFun]

Re: Floor Replacement Made Simple!

Great Job erikgreen!! That is pretty much what I was looking for!! Thanks for the explanation?
I do realize and understand there can be much to this process and that trying to sum it up into a ?Nutshell? can be quite difficult?
But Erikgreen I just had a couple questions to your nutshell explanation:
Do I just use the filler on the edges no where else?? And just the epoxy on the top and bottom??
Also when do I apply the glass to the top, is this ?step 4? or are you still talking about the tape around the edges?
Thanks again this was a great help!!!

 

[erikgreen]

Re: Floor Replacement Made Simple!

You can use the filler wherever you like, but it's critical to use it around the edges to make a nice smooth fillet for the glass to follow. If you don't have a smooth transition between the bottom and sides, then the glass tape have trouble following the angle there and will form a bubble right in the corner, which is the worst spot for it.

If you like you can smooth the whole deck. Probably you'd want to use some anti-skid paint on it after that so you don't slip and slide everywhere, but it's up to you.

I actually didn't have any step in there for glassing the top of the deck, and I really should have. If you want to do that, do it after the tape around the edges hardens, and maybe after you sand any bubbles or ridges.

If you decide to glass the bottom too, you can do it just after you cover the deck parts with the thin coat of epoxy. In fact, you can do one side at a time and glass both at this point, before you install them if you want. It'll require some work to make the transition at the edges where the tape will go look good later (filler), so a lot of people just glass the top once the whole deck is installed.

So, in a nutshell: Glass the bottom of the deck while the pieces are outside the boat. Once it's installed and edges taped, lay down glass on top of it overlapping with the tape.

I do recommend you also read a couple of the links provided above, and maybe do a search here for "deck install" or similar terms. Seeing someone else's pictures of going through the process will let you know what to expect, which will help you do a better job.

Erik

 

[s1120]

Re: Floor Replacement Made Simple!

Call US composites.com , they'll tell you what you need,
there's too many variables for nutshell answers.
Got unlimited funds? go with epoxy.

Thanks for the link to US composites!! Looks like they have some real good prices.


Thanks to the OP for this thred also!! I have been reading threds for the last few days, and having some problem peacing things together to one plan.


Doing a stringer/floor replacement myself. Still thinking of what I want to use. Epoxie, or Polyester resin

 

[NC State Guy]

Re: Floor Replacement Made Simple!

erik,

thanks for your great summary. i've been doing a lot of reading, that summed things up nicely.

i had already purchased some polyester resin/hardener from a local marine repair. they also sold me some fiberglass roll (looks like basket weaving) maybe 3.5 ft by 20 ft.--before i found this website. can i make this stuff work? my gas tank(removed) was between the stringers with an access panel that was screwed in over top of it.. Would it be alright to do away with the access panel to make the floor a solid piece, from one side of the hull to the other?

the boat is an I/O open bow 1980 17 ft searay.

thanks

 

[s1120]

Re: Floor Replacement Made Simple!

my gas tank(removed) was between the stringers with an access panel that was screwed in over top of it.. Would it be alright to do away with the access panel to make the floor a solid piece, from one side of the hull to the other?

the boat is an I/O open bow 1980 17 ft searay.

thanks

Did you move your tank? If so where did you move it to? I have the belly tank also, and that panel over it was where the water got in to rot my floors. I would like to floor over the whole thing also!!

 

[ondarvr]

Re: Floor Replacement Made Simple!

erik,

thanks for your great summary. i've been doing a lot of reading, that summed things up nicely.

i had already purchased some polyester resin/hardener from a local marine repair. they also sold me some fiberglass roll (looks like basket weaving) maybe 3.5 ft by 20 ft.--before i found this website. can i make this stuff work? my gas tank(removed) was between the stringers with an access panel that was screwed in over top of it.. Would it be alright to do away with the access panel to make the floor a solid piece, from one side of the hull to the other?

the boat is an I/O open bow 1980 17 ft searay.

thanks[/QUOTE

It can be difficult to follow sevaral different questions from different people in the same thread, for better answers and so that your project doesn't get lost in someone elses thread it would better for you start your own thread.
To answer your question, yes what you purchased will work fine.