I thought I would start another thread showing my Plas Deck synthetic teak floor install from start to finish
This is what I started with.
Here is a Sample of the Material Im going to use
Plas Deck makes many diffrent colors
I took a belt sander with 36 grit to the floor to smooth it out and remove all the factory glue
Because the floor would end right at the floor joints they need's to be finsihed
All the joints in the boat were sanded and refinished and Epoxy'd Black
All the floor Boards needed to be re made because the thickness of the carpet raised them up to floor level when the carpet was removed the factory boards were 1/2 inch counter sunk into the floor the new boards were made to sit flush with the floor.
The boards were epoxy'd resin'd and then Rhino Lined
After I got the floor boards the right height I could start the template. This is the Material used to make the template. Its a clear plastic
The plastic was layed out and I marked the Joints and the Margins with Blue tape and Black pen
The String is used to mark the center line of the boat
This is a example of a margin. Its the boarder that will go around the motor box
Here is the joints around the ski locker
The Margin going around the boarder of the boat
Once the template was made I rolled it up and shipped it out to the factory in Indiana.
Once Plas Deck received my template they scanned it and sent me a blue print of the lay out
Here is a pic of the floor at the Factory, They will send you some photos to give you a heads up of what it looks like so you can spot problems before it ships
It arrives in a Giant Tube
Out of the tube I layed it out to see what i was dealing with. The material layed flat very quick
I layed the floor out to test fit it
then I pulled small sections of the floor back and layed down the glue
This floor install was part of what seemed like a endless list of improvements. The boat has been off the water for almost 2 Years now. I had a chance to just sit in the boat and look around. I have refinished, tweaked modified updated or replaced almost every piece in my boat including the trailer. Keep in mind its 12 years old. Im so happy to have this off my "to do list" This weekend will be the first outing. Ill take some more pic's out in the sun this weekend.
I've been waiting to see how this project was coming along. Two years??? Wow. I didn't realize it had been that long since you started. Looks great so far. I always love your projects. Keep the pics comin.
Thanks for the all the complements, I don't know if I'm
slowing down or it's because just as I started this project we bought a new boat so the nautique overhaul & teak floor project took a back seet or if the floor portion of this project was to big of a piece to take a bight of? It seemd like every thing effected the next move. The next move was effected by the following move and so on. I couldn't move one way because I had to make or move somthing else before I could do the next item. It was a real chess game. I guess if I did it again I could do it more efficient but If I knew someone would have done it better or taken more care or I thought it would would have come out better it might just be worth the $ to pay them. The template took quite slot of work. And more mental pressure ya see The factory will only make you what you give them. So if you make a crooked or incorrect template guess what your gonna get back! That right a $3000 door mat. It all came out great. I don't think I would have done it any diffrent I would have just had a better Idea how to juggle all the diffrent things that needed to get done b4 I could move on. Working with PlasDeck was great. They helped me threw the template making process and seemd to be intrested in my project and wanted the best possible outcome so that was cool. I don't envy the guys that do the Syenthetic teak for a living at all LOL! If I would have had a finished fiberglass floor like they have in most of the newer boats this would have been 1/2 the work. I had such tight tolerance's in my boat to begin with that the added height of the PLasDeck floor threw everything off. I even had to cut more of the boat away so that the sub box's would slide back in to their spots. I'm super happy to have this the lion share of this project off my back so that I can do some other things.
It was 3k deliverd to my door with all the glue to install it. As you can see I did flooring all threw out the boat. This almost doubled the cost of the floor. The square footage adds up real quick if you want to cover every nook and cranny. Also Margin' s or boarders jack the price up. I could have cut another 5-700 if I went with straight flooring. So theoretically I could have done everything for $1500 if I would have just done the floor where you see and walk and no margins. You can also choose to DIY you can but the raw Material and bud the floor strip by strip. This way you don't need a template. You just lay the material down and start building it as you go. Or you could do a template as I did and then build you floor on a table.
I decided to have the factory do it because I wanted all
The seems factory plastic welded. This way the floor is one piece and their is little chance of any of the seems splitting. I figured do it once and be done with it. This is not a project I wanted to re do!
One more thing. You could choose to do your floor in sections. Example; you might not have enough time or money to do the entire floor. So you could just template just the areas you see and walk on. Then when you have more time and money you could make more sections and add onto the floor. You could just add a boarder or margin where ever there was a stop and start.
John: I'm guessing you have a Nautique 211. Your boat would be pretty easy. The gell finished floor would only mean you would have to template it. I was also going to suggest a cheeper alternitave like SeaDeck but I'm not sure even how much cheeper that stuff is. A friend who works for a dealer said a replacment floor for a G23 was around $2500. The way I look at it is the carpet is cheep, it looks good for about a year or so and them you are constantly trying to keep it looking new and even with all that effort it still looks bad. So your gonna spend $1000 replacing your carpet (if you have some one do it) so if you plan on keeping your boat for some time it's not a bad investment.
Jack; My wife said the same thing about the rails I'm on it!!!
Shawn; yes the triangle seet in the front of the boat would almost bounce out when you were playing loud. If you opend up that seet you could hear a lot more bass comming out it was almost like opening up a hatch or somthing. I had to reinforce that cushion and add in a track that allowed the seet to sort of sit into its place. Now the seet stays in place and bass flows freely out the front of the boat now. So it's pretty much a big O vent. My anchor and rope sits their and it's VERY easy to just reach in and grab a anchor. Works out perfect !
Jack: the PlasDeck is very nice on the feet. It's some what firm but has a rough cut finish (36 gritt) for traction and look and feel of real teak. The nice part is if it gets a stain or mark you can just clean it out or sand it out.
AMAZING G! It's been a bit to where I fell out of your updates and thread... The finish product is more then I expected and that's hard to say. Damn good work and now another 2 years to overhaul the Toon, LOL... I would like to hear the offers you get in the next few years to let go of it.
Speaking of Toon, just seen a pic the other day with duel 300's and did 65 MPH. I would be officially be a Toon Goon with that bad boy!!!