Restoring Your Bayliner: Replacing The Boat Floor Yourself

Replacing the floor of a Bayliner boat is a complex task that requires a range of tools and materials. The process involves removing the old flooring, measuring and cutting new flooring pieces, sealing them, and then installing them. While it is possible to replace the floor of a Bayliner boat yourself, it is important to note that it is a time-consuming and labour-intensive process, often requiring carpentry skills and power tools. It is also important to consider the potential health risks associated with the task, as it involves exposure to toxic substances and hazardous dust. Therefore, seeking professional help or having a full set of protective gear is recommended.

Removing the old floor

Before you begin to remove the old floor, you should remove all seats, consoles, and fixed items from the floor. Disconnect any wiring or connections prior to removing them from the boat.

Now, to the task of removing the floor itself. If the floor is already rotted, it may not be difficult to separate it from the hull and stringers. However, you should still exercise caution to avoid cutting too deep and puncturing the hull. You can use a variety of tools for this job, such as a sawzall, a roto zip cutter, or a small grinder with a 4" disc. Take your time and be careful not to inhale any of the hazardous dust produced by grinding fiberglass. It is recommended to wear full personal protective gear, including a respirator, goggles, gloves, and a tyvec suit.

If your floor is not yet rotted, you may need to use a tool like a circular saw to cut the floor into strips or sections to remove it. Again, be cautious not to cut too deeply and damage the hull or stringers.

Once the floor is removed, inspect the stringers and cross-pieces for any signs of rot. Chances are, if your floor is rotted, other parts of your boat may be as well. You may need to repair or replace these structural components before installing a new floor.

Safety Considerations

Working with power tools and inhaling toxic dust can be dangerous. Always wear the appropriate safety gear, including eye protection, a respirator, gloves, and a protective suit. Be sure to work in a well-ventilated area and take frequent breaks to avoid overexposure to dust and fumes.

Cost and Time Considerations

Replacing a boat floor can be a costly and time-consuming project. If you hire a professional, it could cost you around $2500. Doing it yourself will save you money, but it will still be a significant investment in terms of time and materials. Plan and budget accordingly, and don't underestimate the scope of the project.

Separating the floor from the hull

Firstly, ensure you have the right tools for the job. A "sawzall" and a "roto zip cutter" are recommended by some boat enthusiasts. A "small grinder with a 4" disk" can also be useful for cutting around where the floor meets the hull, although this will generate a lot of dust. For safety, be sure to wear protective clothing, including a respirator to avoid inhaling the dust.

Next, carefully begin to cut and separate the floor from the hull. Take your time and be cautious to avoid cutting too deeply and damaging the hull. If your floor is already rotted, it may release from the stringer without much effort. However, if the floor is still in good condition, you may need to use more force to separate it.

As you work, pay close attention to the stringers (the support beams below the floor). If your floor is rotten, there is a good chance that the stringers are also damaged and will need to be replaced. Cut out any rotted wood and prepare to sister new stringer wood, epoxying and screwing it into place.

Once you have separated the floor from the hull and addressed any issues with the stringers, you can start to cut the floor into sections to make it easier to remove. Use a circular saw set to the thickness of the plywood floor and cut into strips, being mindful of the location of the stringers.

Finally, remove the sections of the deck from the top of the stringers. Be cautious as you work, as the stringers may also be damaged and in need of replacement.

Remember, this is a challenging and messy job that requires a lot of time and effort. If you are unsure about any part of the process, it may be wise to seek professional help or advice from experienced boat owners or repair specialists.

Measuring and cutting new flooring

To measure and cut new flooring for your Bayliner boat, start by removing all seats, consoles, and fixed items from the old floor. Disconnect any wiring or connections before removing them. Take out the old flooring, trying to keep as much of it intact as possible. This will serve as a template for measuring your new flooring.

Leave a three-inch trim of the old flooring around the edge of the boat. This will prevent puncturing the side of the boat and will also provide sturdy support for the new floor. Measure the new pieces of plywood, using the old flooring pieces as templates. Soak the measured pieces in epoxy to seal out water.

When the epoxy has dried, screw the new flooring pieces in place, noting the location of screw holes and marking them on the flooring pieces. Drill new screw holes before laying the flooring down. Cover the plywood flooring pieces with a fiberglass mat and seal in place using fiberglass resin. Smooth off any rough edges with a soft sander if needed.

Drill screw holes in the dried fiberglass mat, and your new flooring is ready to be installed! Remember to take your time and enjoy the process. It's a labour of love that will make your boat feel sturdier and more enjoyable for years to come.

Sealing and installing the new floor

Preparing the New Floor Pieces:

Before you begin, ensure you have measured and cut the new plywood pieces to fit your boat's floor perfectly. It is recommended to use the old flooring pieces as templates for accurate measurements. Now, let's seal the new floor to protect it from water damage:

• Soak the measured plywood pieces in epoxy: This step is crucial to creating a water-resistant barrier. Ensure you completely coat all edges and surfaces of the plywood.
• Let the epoxy dry: Follow the manufacturer's instructions for the appropriate drying or curing time.
• Sand the plywood (optional): Depending on the epoxy finish, you may want to use a soft sander to smooth out any rough edges or surfaces.
• Drill screw holes: Mark and pre-drill screw holes in the plywood pieces. This will make it easier to attach the new flooring to the boat's framework.

Installing the New Floor:

• Prepare the boat: Ensure the boat is stable and supported on a level surface. Remove all necessary components, such as seats and consoles, and disconnect any wiring or connections.
• Remove the old flooring: Carefully take out the old floor, trying to keep large pieces intact. Leave a trim of around 3 inches of the old flooring along the edges of the boat. This will provide support for the new floor and prevent puncturing the boat's sides.
• Attach the new flooring: Line up the pre-drilled screw holes in the new flooring with the framework of the boat. Screw the new flooring pieces into place securely.
• Cover with a fiberglass mat: For added strength and protection, lay a fiberglass mat over the plywood flooring. Use fiberglass resin to seal the mat in place, following the manufacturer's instructions for drying or curing time.
• Sand and drill the fiberglass mat (optional): If necessary, use a soft sander to smooth any rough areas. Drill screw holes in the dried fiberglass mat to prepare for reinstalling the boat's components.
• Reinstall the boat's components: Put back the seats, consoles, and other fixed items on the boat's deck.
• Finish with exterior carpet: For a complete refurbishment, lay exterior carpet or similar floor covering over the new floor. This will provide a durable and aesthetically pleasing finish to your boat's floor.

Remember to take your time, work in a well-ventilated area, and always wear the appropriate protective gear when handling power tools, epoxy, and fiberglass materials.

Reinstalling seats and consoles

Once you have replaced the floor of your Bayliner boat, you can start to think about reinstalling the seats and consoles. This process will vary depending on the type of boat you have, but there are some general guidelines to follow.

First, you will need to gather the necessary tools and materials. This may include a cordless drill, a socket set, screwdrivers, a carpet scraper, and any hardware that was removed when you took the seats out. It is important to keep this hardware organised and labelled, so you know exactly what you are working with.

Next, you will need to measure the space where the seats will go. This is an important step to ensure that your new seats fit properly and that you have enough space for all the components. Take measurements from the inside of the rails, across the rear width of the boat, and from the inside rail on one side to the other. These measurements will help you determine the amount of space available for the seats and the possible seating arrangements.

When you are ready to begin installation, start by placing the seats in the desired location and marking the position of the mounting hardware. Drill holes for the hardware, being careful not to drill through the bottom of the boat. Attach the seats securely, following the manufacturer's instructions.

If your boat has consoles, you will need to follow a similar process. Measure the space where the console will go and mark the position of the mounting hardware. Drill holes and attach the console securely. Be sure to test the stability of the console before proceeding.

Finally, take the time to inspect your work and ensure that everything is secure and properly installed. You don't want your hard work to come undone during a day on the water.

Frequently asked questions