How to actually cut the floor???

[22E6441]

Yes, yes...deck....

I've read through practically all the threads in this forum, and while I can say I know how to do stringers, transoms, and install new decks, I don't know how to best tackle my soft spot. Nothing really does a very basic "how to start cutting your deck" tutorial. All other threads end up doing a full resto it seems....I'm trying to be optimistic, but need best case scenario instructions.

I want to cut out my soft spot and try to patch it.

What is the best way to do this in the most non-destructive manner? I was thinking of drilling a hole and then using a jig saw to cut out the bad spot. I might need to cut all the way to the inside corner of the boat where the deck meets the gunwale, but I don't want to damage the outer hull. How do you cut a hole out and then be able to put in a patch? I don't know where my strings are. Should I instead cut an area out right across the boat? Right from gun to gun and about a foot and half long? Is that a better approach?

 

[92excel]

Re: How to actually cut the floor???

First, you wont find too much help on patch jobs as they are frowned upon 9 times out of 10..

Cutting out the deck.
Use your circular saw. set the blade depth to your current deck depth, normally 5/8. 1/2 inch deck and then 1/8 inch for glass..
Cut out the area you wish to remove.

Edges where the deck meets the hull..
Get a 7inch grinder and a flap disk and grind out where the circular saw could not reach.

Good Luck

 

[ondarvr]

Re: How to actually cut the floor???

Most of the "complete" jobs started as an "I just want to patch a soft spot" project. They cut the floor, find wet foam, do little more checking and find rotten stringers. Not What you wanted to hear, but that's how it normally progresses.


For cutting next to the hull where the circular saw won't fit, use a grinder with a solid metal or masonry wheel.

 

[lowkee]

Re: How to actually cut the floor???

ondarvr is right on the money. I had two 12" diameter soft spots which turned out to equal a new deck, seats, transom and stringers. Pretty much every stick of wood in the boat. Once you lift that carpet, you will see some nasty rot and once you lift that deck, you will cry. It has happened to everyone who has started a resto thread with a 'soft spot'. Some people get lucky and only need a new deck, but not many.

I was seriously nervous about cutting into my deck as well. I just cut a few small areas where I knew there was nothing underneath and used a pry bar to peek underneath. From there I began sawing along the stringers to get bigger pieces out. Near the edges is tricky, so be careful setting the proper depth of your blad and cut a few inches in, as the deck is thin (tapered) near the edge. I'm currently using a 4" and 7" angle grinder with a metal grinding disk to remove all of the fiberglass lips. Before the grinder, I used a metal cutting disk on the 4" grinder to cut the lips down to a managable height.

I know it isn't news you want to hear, but that soft spot VERY likely means a large portion of your deck and the foam (if any) underneath is wet and your only course of action if you wish to keep the boat is to replace the deck, not patch it. If you just want one more season out of it, patch it any way you like, as we have all learned there is no such thing as a 'good' patch job. It all rots in the end.

Oh, and welcome to the resto forum! We're here to help each other, so post your progress for other to learn from!

 

[tintug]

Re: How to actually cut the floor???

I must agree with the other posts.I thought I was going to do a quick patch on my floor too...only to find all the wood was wet and very punkie. So out came the seats,that were rotten on the bottom were they meet the floor.Then a close look at the two councils show rotted wood at the bottom as well.Out with them too.While working on taking them out I noticed alot of hacked up wiring.....guess what?Yep....its gone too...LOL...Then I got to the floor started taking It out and did some foam samples and you probley can guess whats coming next......YEP...its wet and rotted on the very bottom were it meets the hull.I now have a totally gutted hull that should be ready for some Gluvit tomorrow then start to cut the floor out and get it ready to seal.I just wanted to fix the bad spot but once I got in there I found alot of things that would have shown up later.With all the great advice and help on this site it seems to be going well...and the guys here put up with my stupid questions too....LOL..as this is my first rebuild. The only thing I wish is I would have found this boat in the winter time for the winter project.Its fishin weather here now and the walleye are running.But I'll just have to hitch a ride with my buddie till I get her done. I'm going to try to post some pics so I can show the progress as it goes and I am having a good time doing it. Hats off again to the guy's that make this site happen...

 

[leerocks]

Re: How to actually cut the floor???

The best tool imo is the 3inch circular saw from sears as it has a thin blade and laser and vacume hookup that really fits the job. Do you have a ski locker? ther is a video on you tube that shows how to do a patch job but i would recommend cutting down the center of a stringer if possible. You can cut 6 inches or so from the side and screw and epoxy a support ledge in. Hope this helps.

 

[fuzzeywiggler]

Re: How to actually cut the floor???

Check this out:

http://www.youtube.com/watch?v=KqELnDPR0hQ


Fuzzy

 

[83mulligan]

Re: How to actually cut the floor???

I used a grinder with a 4" wheel, sawzall, circular saw, pry bar and hammer. Each one has its place, i guess. you can get pretty close to the hull cutting the glass with a grinder. then you don't have as much of a dusty mess when you go to grind the edges down. The less grinding, the better in my opinion.