Replacing Soft Boards On Ski Boats: A Step-By-Step Guide

Replacing the soft boards on a ski boat is a complex task that requires a good understanding of the boat's construction and the ability to work with various tools and materials. The process typically involves removing the old flooring, preparing the surface, installing new flooring, and finishing the refurbishment. Before beginning, it is important to assess the condition of the boat's stringers, foam, and other components, as issues with these parts can significantly impact the project's complexity and cost.

Removing the old soft boards

Prepare the Boat:

Before beginning any work, ensure that your ski boat is securely supported on a trailer or jacks. This will provide a stable platform to work on and ensure your safety. If possible, work in a covered area to avoid potential weather interruptions. Gather all the necessary tools and materials, including safety gear such as gloves, eye protection, and a respirator.

Disconnect and Remove Components:

Start by disconnecting all electrical wiring and components attached to the soft boards. This includes items such as seats, consoles, and any fixed objects. Label and set aside these components, keeping them organized for easier reassembly later.

Remove Old Soft Boards:

Carefully remove the old soft boards, trying to keep them as intact as possible. Use the old boards as templates for measuring and cutting the new soft boards. It is important to leave a trim of around 3 inches of the old soft boards around the edge of the boat. This will prevent accidental punctures to the boat's sides during the removal process and provide a sturdy support for the new soft boards.

Clean and Inspect:

After removing the old soft boards, take the time to thoroughly clean and inspect the underlying structure. Look for any signs of damage, rot, or water intrusion. Address any issues that may impact the integrity of your ski boat before proceeding.

Remove Old Fasteners:

Proceed to remove all the old fasteners, such as rusted screws and bolts, that secured the soft boards in place. Use appropriate tools, such as a drill or a saw, to carefully remove them without damaging the boat's structure.

Prepare for New Soft Boards:

Once the old soft boards and fasteners have been removed, you can now prepare for the installation of the new soft boards. Measure the required dimensions, using the old soft boards as templates if they are in good condition. Mark the locations of screw holes and other essential points for reference during reassembly.

Choosing the right material for the new boards

When it comes to choosing the right material for the new boards, there are several factors to consider. Firstly, it is important to use marine-grade plywood for the new floor. Marine plywood is made from better materials, has no internal voids, and uses waterproof glue, ensuring its durability and longevity in a boat. Regular plywood, on the other hand, tends to have external blemishes and internal voids, and the glue used is not always waterproof, which can lead to a shorter lifespan.

Another important consideration is the thickness of the plywood. It is recommended to use the same thickness as the previous floor to ensure that the new floor fits properly and does not affect the alignment of the boat seat and hull rivet holes. In most cases, 1/2" thick plywood should suffice.

If your boat floor is wider than the standard 4' x 8' sheet of plywood, you have a few options. You can opt for an oversized sheet of marine plywood, but these can be difficult to find and quite expensive. Alternatively, you could purchase a larger sheet of marine-grade plywood and cut it to size, ensuring that the new floor fits snugly within the boat.

Additionally, you will need to select an appropriate floor covering, such as vinyl or carpet, and the corresponding glue to adhere it to the plywood. Stainless steel staples are recommended for reattaching the floor covering, as they will last longer than regular steel staples.

Finally, you will need various tools for the job, including safety gear such as safety glasses, hearing protection, and leather gloves. Basic tools like a tape measure, drill, and saws will also be necessary, as well as an air compressor and related tools for setting rivets.

By carefully considering these factors and choosing the right materials, you can ensure a successful ski boat soft board replacement project.

Sealing the new boards

Selecting the Right Materials

Before you begin sealing, it's important to choose the right type of plywood and sealant. For ski boats, it is recommended to use marine-grade plywood of an appropriate thickness, typically around 1/2" thick. This type of plywood is designed for marine environments and will withstand water exposure better than regular plywood.

For the sealant, you have a few options. One common choice is to use oil-based paint, which offers good protection. Another option is to use epoxy, which provides an excellent seal and bonds well with wood. Alternatively, you can use polyester resin, though some people prefer to stay away from this option.

Preparing the Plywood

Before applying any sealant, it's essential to prepare the plywood surface. Cut the plywood pieces to fit your boat, ensuring they are the correct size and shape. If you're splicing multiple pieces together, do so now, creating a sturdy and seamless joint. Sand or smooth any rough edges to ensure a uniform surface for the sealant to adhere to.

Applying the Sealant

Once your plywood is ready, it's time to start sealing. If using oil-based paint, apply a coat to all surfaces of the plywood, including the top, bottom, and edges. Allow the paint to dry thoroughly according to the manufacturer's instructions, typically around 24 hours. Then, apply a second coat for added protection. This process will take several days to complete, so plan accordingly.

If you're using epoxy or resin, prepare the mixture according to the manufacturer's instructions. Soak the measured plywood pieces in the epoxy or resin, ensuring all surfaces are thoroughly coated. Again, allow the sealant to dry completely before proceeding.

Finalizing the Sealing Process

After the sealant has dried, you may need to sand or smooth any uneven areas to create a uniform surface. If you spliced plywood pieces together, reinforce the joint by applying an additional layer of sealant over the seam. This will ensure that the joint is just as protected as the rest of the plywood.

Once you're satisfied with the sealing job, you can move on to the next steps of the soft board replacement process, such as reinstalling the seats and other fixtures.

Remember to take your time during the sealing process, as it is a critical step in ensuring the longevity of your new ski boat floor. A thorough sealing job will protect your boat from water damage and extend the life of your plywood.

Installing the new boards

Now that you've removed the old soft boards, it's time to install the new ones. Here's a step-by-step guide:

• Prepare the new boards: Measure and cut the new boards to fit the space. If you're using plywood, seal all surfaces with a good quality oil-based paint or epoxy to protect against water damage. Allow sufficient time for the coating to dry completely. If you're splicing pieces together, use an aluminium strap and large flange rivets for added strength.
• Prepare the boat for installation: Clean the inside of the boat thoroughly, removing any remaining rivet pins and debris. Mark the locations of the hull cross members on the sides of the boat, so you know where to drill holes for the new boards. Inspect the bottom of the boat for any damage, and make any necessary repairs.
• Install the new boards: With the help of an assistant, carefully lift the new boards into place. If you're reusing the old floor covering, align the rivet holes with the cross-member support marks. If not, use your diagram to mark and drill holes for the pop rivets that will secure the boards to the supports. Apply marine silicone around each hole before inserting the rivets.
• Secure the new boards: Use pop rivets to secure the new boards in place. Be sure to use enough rivets along the perimeter and in all the floor supports you've identified. The floor should now be firm and secure.
• Reinstall fixtures: Reinstall any boat seats, storage compartments, or other fixtures that you removed earlier. Align the holes in the fixtures with the holes in the boat's hull, using tapered punches or screws as guides. Install solid rivets to secure the fixtures in place.
• Finishings: If desired, cover the plywood flooring with a fiberglass mat and seal it with a layer of fiberglass resin. Once dry, you can smooth any rough edges with a soft sander. Finally, lay exterior carpet or similar floor covering to complete the refurbishment of your ski boat's floor.

By carefully following these steps, you'll have a sturdy new floor for your ski boat, and you'll be back out on the water in no time!

Reattaching the seats and storage compartments

Once the new floor has been installed, you can proceed to reattach the seats and storage compartments.

The seats and storage compartments are attached to the hull using solid aluminium rivets. To reattach them, you will need to align the rivet holes in the boat hull with the holes in the seats and compartments. This can be done by using small tapered punches or a "Cleco" tool.

Begin by inserting the tapered punch into the hole on the seat flange, and then into the corresponding hole in the boat hull. Push the punch in and twist it around to align the two holes perfectly. If you only have one tapered punch, you can use a 3/16" screw and nut in place of the second punch. Insert the punch in the centre hole and work it around until you can get the screw into either the top or bottom hole. Then, pull the punch out and insert it into the other hole, and the centre hole should naturally line up.

Once the holes are aligned, you can start riveting. Before installing the solid rivets, ensure that the seat flange and boat hull fit together snugly. If there is a loose fit, use the screw and nut to tighten the surfaces together. Then, follow the steps outlined in the previous section on "How to Install Solid Rivets".

Repeat this process for all the seats and storage compartments. By taking your time and working through each step carefully, you will be able to successfully reattach the seats and storage compartments to your ski boat.

Frequently asked questions