Replacing Floors In A 69 Starcraft: A Step-By-Step Guide

Replacing the floor of a 69 Starcraft boat is a challenging task that requires a good understanding of boat construction and maintenance. The process involves removing the existing floor, cleaning and preparing the boat for the new floor, and then installing the new floor securely. The type of wood and fastening method chosen will depend on the specific model of the boat and personal preferences. It is important to carefully plan the project and gather the necessary tools and materials before beginning the work.

Removing the old floor

Prepare the Boat:

Before you start, make sure you have a clear and clean work area. You will need to remove all the seats, storage containers, and any other fixtures attached to the floor. This will involve drilling out or grinding off the rivets that hold them in place. Be careful not to damage the hull or any other parts of the boat. You may also want to take pictures at this stage to help you remember how everything was assembled.

Remove the Old Floor:

Once the interior fixtures are removed, you can start taking out the old floor. Again, this will involve drilling out or grinding off the rivets that hold the floor in place. Take your time and be careful not to damage the hull or stringers. Use the right tools for the job, such as a drill, rivet gun, and grinding disc attachment. You may also need to cut the floor into smaller pieces to remove it from the boat.

Clean and Inspect the Hull:

With the old floor removed, you now have access to the inside of the hull. Take this opportunity to thoroughly clean the hull and inspect it for any damage. Use a butter knife or a similar tool to clear any dirt and debris from the gap under the center of the ribs and the aluminum sheet of the hull. This will improve drainage. Also, check for any leaking rivets and fix them.

Remove Old Foam:

Now is the time to remove any old foam or flotation material that is saturated or damaged. Cut or pull out the foam, being careful not to damage the hull or any other parts of the boat. You may want to wear protective gear during this step, as the foam may release dust or chemicals.

Template and Measure:

If possible, use the old floor pieces as templates for your new floor. Measure and mark the pieces carefully to ensure an accurate fit. You may also want to create cardboard templates if the old floor is too damaged. Mark the locations of the stringers, ribs, and other structural elements to help with positioning the new floor.

Prepare New Flooring:

Before installing the new floor, prepare the plywood or composite material by sealing it with epoxy or another suitable treatment. Follow the manufacturer's instructions for the best results. Cut the new flooring to size, using your templates or measurements. Treat the edges and all sides of the plywood with epoxy or sealant to protect them from water damage.

Remember to take your time, work carefully, and wear appropriate safety gear during the removal process. It is also a good idea to have an extra pair of hands to help with drilling, grinding, and lifting. By following these steps, you will be well on your way to successfully replacing the floor in your 69 Starcraft boat.

Choosing the right material for the new floor

When it comes to choosing the right material for your new boat floor, there are several factors to consider, including durability, maintenance, cost, and aesthetics. Here are some options to consider:

Marine-Grade Plywood

Marine-grade plywood is a popular choice for boat flooring due to its durability and resistance to rot in high-moisture environments. It is made from high-quality materials, has no internal voids, and uses waterproof glue, making it a long-lasting option for your boat. While it may be more expensive upfront, marine-grade plywood can save you money in the long run. When replacing the plywood, it is recommended to use the same thickness as the previous floor to ensure a proper fit.

Synthetic Decking Materials

Synthetic materials, such as PVC, composite board, marine board, or synthetic teak, are increasingly popular choices for boat flooring. These materials offer superior resistance to rot and decay compared to traditional wood. They often require less maintenance and can provide a long-term solution to prevent future deck rot. Synthetic materials may also offer a wider range of colour and style options, allowing for customisation and a more modern appearance.

Treated Lumber

If you are considering using treated lumber, it is important to note that certain chemicals used in the treatment process can react with and corrode aluminium. This can cause damage to the hull and other components. Therefore, it is generally recommended to avoid using treated lumber in aluminium boats.

Foam

Using foam underneath your boat floor can enhance buoyancy and provide additional support. However, it is important to use a closed-cell foam specifically designed for this purpose, as standard styrofoam is not suitable. A two-part pour-in foam is commonly used and provides effective flotation while also allowing for water drainage.

Carpeting or Non-Skid Gel Coat

While not specifically flooring materials, the top layer of your boat floor will also require consideration. Carpeting can provide a comfortable and slip-resistant surface, but it may be more prone to water absorption and can be more challenging to clean. Alternatively, a non-skid gel coat can offer excellent traction while being more resistant to water and the elements. This coating is applied directly to the flooring material and can enhance the overall durability of your boat floor.

Fixing the new floor in place

Once you have your new floor cut to size, it's time to fix it in place. You have a few options for how to do this. One method is to use self-tapping stainless steel screws. Another option is to use blind rivets. Blind rivets are preferable if you want to avoid making holes in your new floor, as screws will pierce through the wood.

If you are using screws, be sure to use stainless steel ones. You can use a marine sealant like 3M 5200 or 4200 to seal the holes. This will help to prevent leaks. Apply the sealant to the screw after it has been inserted into the hole.

If you are using blind rivets, you will need to use a rivet gun to set them in place. It is important to use the correct type of rivet for this application. Open-end blind rivets are not suitable for through-hull applications, so be sure to use closed-end blind rivets. These rivets are water and vapour-proof and are commonly used in the boating industry. You can use an ordinary pop rivet tool to set rivets up to 3/16" in diameter. For larger rivets, such as those that are 1/4" in diameter, you will need a heavy-duty setting tool.

When replacing the floor in your Starcraft boat, it is important to make sure that all the fixtures and fittings are removed first. This includes seats, storage areas, and the console. These items are typically attached to the hull and floor with rivets or screws. To remove them, you will need to grind off the backs of the rivets from the inside of the boat. This can be done with a grinding disc attachment for a drill. Once the rivets are removed, you can then remove the fixtures and the old floor.

When installing the new floor, be sure to clean the area first. You can use a product like Gluvit to seal the inside of the hull and protect it from corrosion. You should also consider adding flotation material such as closed-cell foam or pool noodles before installing the new floor. This will help to improve the buoyancy of the boat.

Finally, you can finish your new floor by painting it, covering it with vinyl, or adding marine carpet. If you choose to paint it, be sure to use a marine paint that can withstand the rigours of boating. You can also add a non-skid additive to the paint to improve traction. If you choose to use vinyl or carpet, be sure to use a marine-grade product that is designed to withstand water and sun exposure.

Using foam for buoyancy

When replacing the floor of your 69 Starcraft boat, you may want to consider using foam for buoyancy. Here are some things to keep in mind:

First, it is important to use the right type of foam. Do not use standard styrofoam, but instead, opt for a closed-cell foam. This type of foam is often used for flotation and will provide better buoyancy for your boat. It is also important to note that the foam should not be in direct contact with the aluminium of the boat, as the chemicals used to treat the wood can cause a galvanic response and eat away at the aluminium over time.

When installing the foam, you have a few options. Some people choose to cut the foam with a knife to fit the shape of their boat, while others prefer to use a two-part pour-in foam that expands to fill the space. If you choose to use the pour-in method, make sure to create a gap underneath the foam for draining and give it room to expand. You can also use PVC pipes with holes drilled in them, placed lengthwise down the floor, to allow for air circulation and water drainage. Cover the PVC with pre-cut foam, as the pour-in method won't work in this case.

Additionally, consider filling the gap under the centre of the ribs and the aluminium sheet of the hull with foam. This will help with underfloor draining. Make sure to clean this area first to remove any dirt and debris build-up.

Before installing the foam, make sure to leak-test the hull and fix any leaking rivets. Use exterior-grade plywood for the flooring, primed and painted on all sides and edges to protect it from the elements.

By following these steps and using closed-cell foam, you can effectively use foam for buoyancy when replacing the floor of your 69 Starcraft boat.

Sealing the hull

Step 1: Identify Leaks and Problem Areas

Before you begin sealing, it's important to thoroughly inspect your boat for any leaks or problem areas. Pay close attention to seams and rivets, as these are common sources of leaks in aluminium boats. Check the entire boat, including the hull, deck, and fittings, to identify any areas that require sealing.

Step 2: Clean and Prepare the Surface

Once you've identified the areas that need attention, it's time to clean and prepare the surface. Use a dedicated aluminium boat cleaner to ensure a thorough cleaning while protecting the metal. Allow the boat to dry completely so that you have a smooth, clean surface to work with.

Step 3: Choose the Right Sealant

Selecting the appropriate sealant is critical for effective hull sealing. Choose a sealant specifically designed for metal adhesion, such as a silicone rubber sealant or a product like Life-Calk, which adheres to metals and won't corrode them. Avoid using sealants with solvents, as they can cause bubbling and discolouration.

Step 4: Apply the Sealant

When applying the sealant, be generous. It's better to apply too much than too little, as you can always scrape off the excess later. Follow the directions on your chosen sealant for proper application and curing times. Some sealants may require an overnight cure, so plan accordingly.

Step 5: Inspect and Test the Seal

After the sealant has cured, inspect the sealed areas carefully. Test the seal by exposing it to water and ensuring that there are no leaks. If necessary, you may need to apply a second coat or make touch-ups to ensure a watertight seal.

Tips and Tricks:

• Always read the label and instructions on your chosen sealant before use.
• When in doubt, opt for a sealant designed for marine use, as these are formulated to withstand water and weather conditions.
• Consider using a sealant that can be painted over if you wish to match the colour of your boat.
• For small hairline cracks and leaks, an epoxy sealer like Travaco RM330K Gluvit Epoxy Sealer is a good option.
• If you're sealing around fittings, consider using butyl tape, which is easy to apply and provides a watertight seal.

Frequently asked questions