96 ski nautique floor removal....help/ideas/tips!!

Hey KRoundy!, I went through your blog again a couple nights ago, looking good!

Hello everyone,
To update, I had great intentions of working all winter on the boat and it didn't happen. Currently I am 90% done removing the foam and floor. Generally just prepping to refoam and glass. With the help of another member via private message I have started a material list from US composites but would really appreciate the input of those experienced so I order the exact materials and amount. I'm from Canada so don't want to screw up the shipment.

80lb kit of 4lb density foam
2 gallon plus 1 gallon kit (total 3 gallons) medium epoxy kit
20 yards of 17oz biax 50"(includes floor and tops of 5ftx1ft stringers cut open)
3 rollers

I am unsure which biax to use as there are a couple types and the original floor seems to have a top layer of strand and lower layer of woven mat cloth...I want to keep it as close or better than original.
I also have a 2x4 area in front of observers seat I have to cover with either marine plywood or coosa.
I could also call us composites and describe the job, anyone done that with success?
appreciate the help!
As suggested previously I will get some pics out, first one being when the floor prep is complete.

Tim,

Thanks for the clarification on the dehumidifier option. Wet foam is not something they I've had to contend with on race boats. It must slow draw in water (osmotic?) then trap it in a closed cell.

Charlie

Holy cow! Look at that composite boat. I wondered what mine would look like if I had cut out the entire floor. Now I know. How wet was it? Interestingly, the foam in the tree-killed boat was mostly dry. There was a little water on the bottom of the hull, but that was basically it. You have put in a lot of work there. +1 on removing the engine to make things easier on yourself. Once that big hunk of metal is in the way it is odd how small the boat suddenly feels.

Please keep us up to date on your progress.

Can you tell me why you want to remove the stringers? There is nothing wrong with them.

I wonder what that blue foam piece under the driver's seat does?

+1 don't go thru all this work then cut corners on resin. Epoxy will adhere to all other resins too,poly will not. Being in Canada changes things but check out US Composites

Okay, hoping these pics uploaded correctly....anyway, Kevin, thankyou for getting back to me! Your blog has been very useful, especially the cross section of the bow from the nautique you cut up. I am going to spend a couple more days cutting out the rest of the floor to remove the remaining foam then think about blocking her up in the garage to prep it for glassing (with poly resin)when I have time so I can slow down :) I also cleaned out the hull with a garden hose yesterday and looked underneath to find water dripping out of the rudder so will likely replace the stuffing in that this winter and reseal my tracking fins. Otherwise, thanks for the help. Ohhh, the dehumidifier suggestion may have worked if I hadn't already completely destroyed my floor, knowing that may have worked kinda hurts a little :) Has anyone ever done this with success on a nautique??? Might be something to try down the road.

KRoundy, don't know how I missed your rebuild blog. That is great information and helpful pictures. What a project....very nice

Scott,
I got the PM and responded today. Email me! I have more photos that I can send if anybody wants to know what it looks like underneath the floor of a 1993. Ryan - that link brings back so many memories! Awesome. If you'd like to dig deep into my boat project this link has almost anything you need (including details on the floor repair and photos of a cut-up 1993 SN):
My boat blog

I think that you are perhaps hitting the tunnel that goes near/under the driver's seat area. The stringers are quite a distance from the floor for the most part. If you are cutting with a cutting wheel or making sure you stay shallow with a saws-all you should be OK. But - as has been suggested - go slow!

I also think it would be a good idea to drill a 1" hole and see if you find wet foam right away. Could you post a photo of your boat sitting (not moving) in water?

I've been really busy with work and not on here as much. Sorry for the delay in response.

Thanks for the help, the 93 brochure is exactly what I needed about 2 weeks ago! So far I have cut about half of the floor out including the starboard stringer. I mistakenly had drilled a holesaw into it which revealed wet foam inside so I cut the top off of it as well to remove the foam. Not sure if I will leave the stringer alone on the port side, probably will kill me not to check for water so likely will cut into it. From the front of the engine to the bow has an original layer of glass, then a layer of blue hard foam, then quite a few layers of glass over this to finish up the floor (later will post cross section pics). I have cut out little sections to access the foam so far in this area (looks pretty ugly right now). I am gonna continue on the port side later this week. The very upsetting result of all this dirty work is that I only am up to 140lbs of wet foam so far which is a lot less than I had figured. Ironically, I'm hoping the remaining sections are full of water! Dreaming...I did read a lot from KRoundy which has been nice, and you are correct, every day I work on this boat I worry about where the heck the water is getting in to all these separate chambers..... For the most part the foam near the surface is dry and the bottom is usually wet but did it enter from the surface and gravity to the bottom or start from the bottom???? I want to dump it into a tub of dyed water after I am done to see where the water is getting in!! I do have a bunch of pics for reference and could make up a "how to" later when I have some time but I'm working against mother nature up here in Canada as it could snow any day now. Thankfully the weather has been very good lately. I also am contemplating taking the boat in to a fibreglass repair shop after I remove all the foam and clean it up so they can glass in a new floor. Anyone have an idea on materials costs to do this myself vs getting someone to do it for me. Also is glassing something I can do indoors (inside my garage) or do I need to be outdoors for ventilation. It's an attached garage and I don't want to stink up the whole house. Between work and this damn project my 3 little boys are wondering where the heck daddy is and why he never plays with us anymore!

The "new" closed cell foam is supposed to be a lot better than the old stuff that was basically a sponge. But, I think it will still absorb water (albeit at a slower rate). I dont think an apples to apples replacement exists- but you can certainly go about putting the boat together differently and still meet the design intent of the original foam (strength and buoyancy). The most common no-foam build involves additional support members to replace the strength lost and help support the floor. Foam can be added under the gunnels instead, if youre worried about the boat going to the bottom.

Joe's boat:

I would not worry about removing the foam from inside the stringers. Its not in the same cavity, so less likely to have become waterlogged... and even if it is wet, its not adding an appreciable amount of weight compared to all of the other foam. Its still providing enough strength to the stringer even if soaked, and isnt in danger of rotting anything out... so just leave it.

Looking at the section thru the floor there appears to be (2) stringers, one adjacent to the bilge where the engine cradle would attach and another where the wooden secondary is typically located. Reading the assembly description would lead me to believe there is no foam in the stringer cavity, what do you guy's think?? If there is foam what a PITA it will be to get at it.

I would drill some small holes in inconspicuous places (i.e. under seat frames) & poke a wood dowel down into the foam to verify the moisture problem before tearing it apart.

Thank you Gary S!....I read a little on KRoundy's posts and am going to pm him.

How do you know your foam is wet?

Is the boat riding low?

Chris