Floor and Carpet Project Underway (Heaven Help Me and My Boat!)

[TexasJT]

Well, I took the plunge and started the carpet replacement, floor repair project on my 1988 Startos 181-PRO. I will get some pictures to post as I go along.

Couple early questions...
- When I push down on the foam under the floor, it compresses and water seeps out. How do I remove the foam?
- What do I replace it with?
- If I kill my boat due to lack of skill will I have to fish from the bank in Heaven for all eternity?

Thanks...Jim


Modified by TexasJT at 6:06 AM 9/8/2008


Modified by TexasJT at 6:06 AM 9/8/2008


Modified by TexasJT at 6:07 AM 9/8/2008

[Scrapper]

LOL

No...God will just put you on shirtless fiberglass sanding duty for eternity! lol

Really though...WELCOME and your in the right place.

The foam either needs to air out or be taken out and new poured in or sprayed in. There are many that have used a pourable type I believe...I have read it before...I know Aarron let his air out...but it all depends on how water logged it is. I would say if its on a deck it would be pretty thick and probably needs to be taken out and replaced. That water logged foam will really slow you down and has a chance of wetting wood if there is any exposed anywhere under the hull. You will need to probably remove a section of floor to get access to the foam. Would probably be a good idea anyways so you can check any surrounding foam that you are not able to get to.

Get some pics up so we can check it out!

[ProcraftMike]

I had pretty good luck using a wet/dry vac to suck the moisture out of the foam in my boat. Just stick it over the top so it seals against the foam and suck away. If you have time on your side and can get the foam exposed to air and it will help dry it. It will take some time, depending upon the thickness of foam.

[delee36]

the only way I know to remove the foam is to get in there and pull it out.
I cut my foam with a knife and pryed it out with a good stout scraper. Did not take very long.

as far as it drying...you want to finish the soon right? Just by happenstance my boat sat open to the air for 2 weeks...about the top 1/2" dried...was soakin freakin wet under that. I just will not dry well. IMO once it is wet...it is ruined.

replace it with two part uerathance foam from just about anywhere...US Composites...Jamestown Distributors ( I had GREAT luck with this company)..iboats...
the explanation of the foam and the can makes the foam seem like a scary thing...it really isn't though. they say has to be poured in 30 seconds or whatever...which seems like it is too fast...but so long as you do not try to do too much area all at once and keep materials close at hand....it is pleanty of time.

mix it in small batches and pour it in evenly and it is a fairly straight forward job. I used two cheap mixing cups ( one for each component of the foam) so I could measure it....then poured both into a coffee can and mixed and poured.

[TexasJT]

Well, I got lucky on the foam. I pulled the entire old floor out and did some digging around and found that wet foam is not an issue. I have had to sand some off several areas as the foam was buckling the old floor from underneath.

I purchased a piece of 3/4" exterior plywood and a can of polyester resin. Do I have the right materials and what are tips and recommendations as I install the new floor?

Thanks in advance for any assistance.

[delee36]

I would have used an epoxy resin, but poly is okay, since you are just waterproofing with it. You will not be able to use the poly resin to patch any holes or make any attachment to the existing boat however. Poly will not adhere to epoxy resin ( and it is almost a guarantee your boat is built with epoxy resin) Epoxy resin sticks to poly, but the poly will not stick to epoxy.

I would be sure to lay mat in the resin ( maybe you plan on it and just did not mention it) The floor takes alot of abuse and flexing and the mat will help keep it solid and keep the resin from popping.

Hopefully ProCraft Mike, Swat or one of the other guys will come along with suggestions for you. They have a truckload more experience with floor replacements than I do.

[TexasJT]

DE - Thanks for your advice. I went and picked up some West System epoxy resin and put another coat on the installed flooring and used fiberglass tape with the epoxy resin on all seams.

I don't have any mat on the floor, just 3/4" exterior plywood sealed in poly and epoxy resins. I plan on sanding down a couple spots in the floor before my final epoxy resin coat. Should I add mat to that coat (I'm not sure what it is)?

Thanks Again...

[delee36]

I think if you have taped all the seams and all you will be fine. The mat is not a requirement. The fiberglass mat...

http://www.jamestowndistributo...s+Mat

is a just an added bonus. This particular mat is preferred with polyester. there are other styles with a bit looser weave which should work better with epoxy.
I think this is preferred with poly resin because it is a bit thinner and dries slower so it has time to wet ( soak) through the mat better...but maybe someone else can come along a verify that.

[ProcraftMike]

Yep, epoxy resin is the way to go when working with wood. It is superior to poly. You made the right choice by getting some epoxy resin. Believe me, you don't want to be doing this repair again. I believe epoxy resins will work fine with most fiberglass cloth. I normally wet the surfaces first, add the cloth over the top and wet it down good. You can tell when it is saturated, as it will turn from white to a wet grey color. Make sure you work all the air bubbles out.

[TexasJT]

DE and Mike - Thanks for your guidance to this point.

Here's where I stand...floor is epoxy resin over fiberglass mat. There are a number of random "hairs" sticking up out of the floor. Should I knock them down with a sander or put on another layer of epoxy? I don't want them poking into or through the carpet.

She's starting to look like a boat again and I want to do right by her.

[ProcraftMike]

Random hairs?? I assume you mean some loose strands from the fiberglass cloth? If so, I normally just take a knife and cut them flush with the surface. Put several coats of resin on the floor. You want to make darn sure that it is sealed up, so water can't get in.

[delee36]

knock em off with a knife or side cutters AND put another coat of epoxy on the floor.
like Mike said...a little extra epoxy on the floor sure aint going to hurt anything.

we are going to get pictures soon right????

[TexasJT]

I'll take some pics tonight.

I'll cut off the rogue fiberglass strands. Is there anything else I need to do before putting another coat of epoxy resin on? Would there be any benefit mixing in some West System 407 filler to the resin to thicken it just a touch to fill low spots and create a smoother base for carpeting?

[TexasJT]

Well, here's where I am today...




A couple questions...
- I need to re-install my latches. What's the best way to cut the carpet out of the holes where the latches go?
- Should I clean and/or treat the aluminum lid hinges? If so, with what...WD40, silicone spray, etc...?

Next project...???
I don't care for the light blue bottom paint. How difficult is it to change to another color?


As always, many thanks!!



Modified by TexasJT at 9:08 AM 9/8/2008

[arjone01]

Use an old sodering iron. Cuts and seals all at once. Just follow the inner circles.

As well, as for color, may check this stuff out.

http://cgi.ebay.com/EPOXY-RESI...wItem

[Legend Chris]

I used an ice pick thingy to find the holes then screwed them in..