As the off season is fast approaching up here in the great white north, I should really be replacing my floor's rotten core (soft just forward of the rear bench).

I remember a few posts that touched on this.... obviously, the first step is to cut away the bottom glass (I'm guessing it was encapsulated) and remove all the wood core.

For core replacement, I'm guessing I need marine grade plywood, or does it matter? Where can marine grade plywood be sourced? Anybody know the thickness of the plywood in a 272's floor?

And lastly, what's the "right" way to bond the new core to the underside of the original glass/gelcoat upper surface (resin?), glass it in, etc.?

Any info and hints would be appreciated.

Thx.

Your better off with marine ply but there are alternatives, its really the way it is installed and cared for that adds to longevity. Most core failures are a result of improper sealing and poor lamination techniques. Marine ply is generally twice the cost of just an outdoor rated panel but in the end its not a whole bunch of money. I prefer marine on most projects because the panels are nice and straight/true plus the have a nicer sanded surface. I am doing a transom at the moment and three sheets of half inch was right around $180 where as three sheets of some off the shelf outdoor rated pine would still be just over a hundred plus pine is not a good core.

Most cities have smaller specialty lumber shops that you kinda have to look for to find, ours does cabinet grade and higher end woods.

I have seen some Formula floors that were just half inch and thats fine as long as there is enough support. Dont be afraid to re engineer your structure but be smart about it.

I will try and get more in depth on the process, just pinched for time at the moment

Put up some pics if you can or as you go

working on a similar project.. pulled my floor and tank..stringers seem good core good..but tank looks like has pin holes starting..gues going to have a tank made..

speaking of weather ..what would be coldest temp to do fiberglass work

While I don't have an exact answer for you, I can tell you I have done epoxy and glass work/repairs on ice boats in semi heated garages in the middle of winter, we leave those big yellow halogen work lights pointed at the work area overnight for heat and it seems to kick off/cure fine.

sixtyish but if you can add some heat you can take it a little lower.

What do you guys use final coat in the floor....... Awlegrip?

I'm putting carpet back that's how it was original..

Dave, once I remove all the old core.... What do you reccomend to bond the new wood to the underside of the original floor?

Thx!