That Gunmetal Gray looks great on there and you've done an awesome job!
I'm at the glue-stripping phase of this same project on my PT 165 (
http://www.bbcboards.net/showthread.php?t=787416) right now and I can attest to the abundance of carpet on these boats, even my smaller, older model. Fortunately, the widest point on my 165 is only 68", so I should be able to get by with the 6' roll. I'm looking at using basscarpetbuys.com, too, since it's only $7.99/ft. I'll probably use the same color as you, but I have some samples en route before I decide. I'm going to take measurements for every square inch of deck/trim/lids/etc. and try to diagram everything using design software so I can use the roll as efficiently as possible and get by with buying as little as necessary. Then again, that 10/ft minimum order might come back to bite me if I don't get it right. I should probably order a few extra feet in case of the inevitable screw up on my part.
The flat SS self-tapping screws were an absolute PITA for me on the floor of my boat. They were so brittle and my drill instantly stripped the heads when I tried to remove them. I ended up having to drill holes around the edges of at least a dozen screws until I could fit my vice grips around the head. I had already planned on replacing the wood, so it's not that big a deal. It just caused a 15 minute floor removal project to turn into about 4 hours of work.
Question: How's the cushioning with their 20oz carpet? I'm sure it's a solid upgrade from the factory carpet, even when that stuff was brand new. But do you think regret not adding a layer of carpet padding on the decks/floor? I'm considering it for my project, but I'm not convinced yet that I really need it.
Another question: I'm planning on extending my deck all the way to the front of the back of the console (steering wheel side) so I can fit up to 7'6" rods. The center will be one large center rod locker and I'll add 2 small utility storage lockers on each side like the new PT 195's:
In order to do this, I need to cut out some of the foam in order to fit the shape of the aluminum frame and sheeting I'm going to rivet in. Did you have to cut out any foam? I think you mentioned you had a water-logged patch...what's your recommended method of doing this? Also, did you replace the cut-out foam, or just leave it out? My foam is bone dry since it's been sitting in my garage for a year, but before I got it, it was sitting outside uncovered for 10+ years. Any ideas on how to tell if the foam is bad even though it's no longer holding water, or is it OK so long as it's now dry and aired-out?
Sorry for all the questions - just trying to take advantage of the experiences of those that have come before me!