Cracked fiberglass deck?

[lee]

You could put some resin on the center section if you wanted but it is not needed. On the main floor I would put just enough resin to soak into the wood and not build it up too much. The carpet will hide its edge better if the floor is lower than the gelcoat.

[Yojax10]

Yeah, I was not planning on building it up all the way to the gelcoat, I figured that would just be a waste of materials, I did want at least try to build it up somewhat to the fiberglass that is on the deck that I am not removing so that there is somewhat of a smooth transition from new to old. However, that may be a bit of a pain since the original varies in thickness from 1/8" to probably just under 1/4". Correct me if I am wrong but it appears that the original application looks to have gone like this: Resin - 1 layer of chop/resin - A layer of resin to as a leveling to try and even things out.

I will probably go ahead and throw a layer of resin on the middle section. It will make me feel a little better about buying a Gallon of resin. I think I could get what I need done with a quart size, but my luck I will run out with a square foot to finish.

[KoolAid]

The entire floor was covered with a layer woven fiberglass. Chop was not used during that time period. The deck was then placed on top of the hull/floor. After the hull and deck was mated they used cabosil mixed with resin to build up the area from the floor to the gelcoated edge of the deck. That is why I was saying Bondo would work just fine. Its not worth buying the cabosil for your application when you can easily buy a tub of bondo. Put it on and shape it just like you would on a car. Always get the bulk of the bondo filed off before it cures. Otherwise tons of grinding :-)

Get the gallon for sure if this is your first time messing with FRP's. Just in case you get the catalyst ratio wrong on your first batch.

[Yojax10]

Well, this past weekend I took the plunge.
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Once I removed all the carpet, I am left with a gap in in the sides and vertically that I will need to address since I am not going back to carpet. I thought about somehow building this up, but I think it will not be worth it in the long wrong. I am thinking it will be easier and quicker to just pick up a sheet of marine ply from Menard's for $66 and recut a new middle section.

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And after some chiseling, grinding and sanding, this is what I am left with. I decided I am going be using fiberglass and epoxy resin to resurface this, as I can use the material for other projects in the works. Plus I will be needing the epoxy to bond 2 pieced together to buildup the thickness I need for the replacement middle section anyway.

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[KoolAid]

Cut a new floor would be your best bet. Only other choice would be to lay a layer of woven over the top of the piece and wrap it around the sides to help with the gap. Then add strips to the bottom to help raise it up.

[Yojax10]

Cut a new floor would be your best bet. Only other choice would be to lay a layer of woven over the top of the piece and wrap it around the sides to help with the gap. Then add strips to the bottom to help raise it up.

Yeah, that is the conclusion I came up with as well. I thought about trying to build it back up, but I figured by the time I did all that, I would have spent more time than it was worth and probably still would not have been happy with it.

[Yojax10]

I have a few questions. For those that have Deckadence, vinyl loop floor mat, miner's moss..... Do you keep the material on the deck when trailering? If so, do you have any problems with it catching wind or anything?

Next, I am sure these are a matter of preference, but do you think I should do one piece that extends all the way up the bow walkway, or should I do a two piece, like the original. If I do one piece, do you think it will look goofy at all where it ramps up from the height difference? What are your thoughts?

[NICKYPOO]

Im going to be doing this in my buddy's 01 21v in a few weeks. I don't think that center piece is going to be quite that easy to replace. It should be a couple of different pieces of marine ply sandwiched and then glassed. Do you have any pics of the underside and edges?

[Yojax10]

Yes, it is two pieces of 3/4" ply laminated together, it looks like it was only glassed on the underside, not the top. I may be missing what is going to be difficult about replacing it (To be fair, I often do underestimate until I am in the middle of actually doing it). From what I can see, the only problem that I may run into is that I need more height than the thickness of the one sheet. If that is the case, I can cut both layers the same size, laminate them and then use my table saw with a dado blade to get the thickness I need to sit flush. The only difficulty here, would be you would probably need a nice table saw and dado stack, which luckily for me, I do. If not, you could use a router to achieve the same goal. OR, option 3 if you laminate both pieces together with the lip already cut, and find that this is not enough height, could you just build up that lip with some fiberglass until you get the height?

I have a picture, but this work computer is not cooperating with me right now, so I try to post it later from home.

[Yojax10]

Persistence wins! Here is the pic that I have. If you want any other view, let me know and I can take one tonight.

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[NICKYPOO]

You forgot the really poor man's dado machine, the skill saw. Don't laugh too hard, I've done it.

Rarely is anything "just that easy" in a boat. I've looked at that piece pretty close in my buddy's and replacing it is deffinitely not simple. Sounds like you've got a pretty good grip on that deal though. Keep us updated on it.

Fwiw, I would do the bow walkway as a separate piece. Having it connected where it would be connected would make install a pita. The front left corner of the main cabin is going to be really thin. You've got a natural break already with the transitions from glass to wood. Why not use it?

[Yojax10]

You forgot the really poor man's dado machine, the skill saw. Don't laugh too hard, I've done it.

Ah, yes! How could I forget the circular saw! I've been there, as well.

Rarely is anything "just that easy" in a boat. I've looked at that piece pretty close in my buddy's and replacing it is deffinitely not simple. Sounds like you've got a pretty good grip on that deal though. Keep us updated on it.

Yeah, I should have learned my lesson on that already this off season. I thought the same thing with the second battery project and ended up rewiring the whole boat.

Fwiw, I would do the bow walkway as a separate piece. Having it connected where it would be connected would make install a pita. The front left corner of the main cabin is going to be really thin. You've got a natural break already with the transitions from glass to wood. Why not use it?

That is what I was thinking. The only thing I need to work through is how to keep that small walkway piece in place, as I think it will slide around. I could use the existing snaps, but I don't think the Deckadence type material will hold a snap well.

[NICKYPOO]

You could always take that bow section to an upholstery shop and have them finish the edges and corners to where they could install some snaps into the material they would use.

[Yojax10]

Got some work done today on the middle section.


Cut the bottom (smaller) piece first
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This piece sits on the hose coming off the gas tank, so I needed to notch it out. FYI, a large can of pumpkin is a pretty close 4" circle.
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Checking the fit.
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Larger, top piece cut and fit checked.
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Laminating the two pieces together with some epoxy. Hope I have enough clamps.
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[Snowline Academy]

What year and model boat is this? I have a 2006 20V I want to pull the carpet out of and put down Gatorstep flooring. However I want to avoid the wood flooring and releveling project. Does anyone know if the 06 20V has a full fiberglass floor or if it has fmmarine wood inserts like this one? Thanks!