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The end?
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While prepping our boat for its first outing this year, noticed some soft spots in the floor - it had turned to compost.
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I don't even want to know what was fermenting under the fuel tank.
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Deconstruction begins
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Seat bases removed
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There's something inherently wrong with taking a circular saw to the floor of your boat.
Out come the seat bases.
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The floor had the most rot around the ski door. The expansion foam was waterlogged and had to be removed.
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Next the floor
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Floor is out
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The floor is completely removed, as well as the storage areas in the bow, and under the dash.
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With the older stringers out, now we start on the new.
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Starting New Stringers
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New Stringers Complete
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Stringers are complete and laid out - next comes the fiberglass...
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The stringers are fiberglassed in - next is the mid section of the floor.
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Stringers In, Now the Floor
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Floor sections Fiberglassed
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As with everything else Each side is convered top/bottom with 1.5 ounce chopped strand mat.
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All floor sections have been fitted, and are finally ready for installation. Each section has been filled with 2-part floatation foam - a fun science experiment...
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Floor Fitted and Ready to Install
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Bow Storage
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Bow storage areas get fitted next.
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Making sure everything is aligned correctly, it gets one last check before being disassembed,fiberglassed, reinstalled and the front section filled with floataion foam.
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Bow Storage Installation
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New Seat Bases
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Seat bases need to be constructed next.
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New seat tracks are cut into the side panels, prior to the real side panels going on. Made a little mistake in the assembly as you can see in the previous pic- the end pieces should have been sandwiched in between the side panels. This fixed the mistake, and made for a stronger base. Should have been this way in the first place ;-)
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Fitting Seat Tracks
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Repairing the Seats
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Dry rot....
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Using what's left of the old for a template for the new.
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Disassembly
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Repaired seats.
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The existing upholstery was in good shape, so I reused it over the new seat base.
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One side is completely rotted away...
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Hydraulic Pump Bracket
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Repaired Bracket
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After sandblasting it clean, I fabricated a new section and welded it in.
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New floor material is glued and ready to go down.
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Prepping the new floor
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Floor material is down
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Getting there - more work and fewer pictures as I get closer to the end...
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All back together. You can see the repaired hydraulic pump bracket on the left.
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Engine Compartment
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Back together...
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Everything is back, carpet installed, etc
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...and my crew is ready to hit the water.
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Crew is Ready
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On the Water
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Finally getting ready for a test run at Harrison Lake.
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