88 sea ray floor from hell

[Chadomosis]

Looks like I've joined the "Sea Ray fix the rotten floor and stringer" group. I'm a tradesman, so I really enjoy difficult projects like this. My question is, I'm thinking I'd like to replace the floor and stringers with PVC and aluminum instead of wood eliminating a lot of glass and probably weight. Any thoughts? Anyone done something similar? Anyone see problem I might run into? I'm at the very beginning of this adventure and any foresight would be appreciated. All of the threads that I've seen so far, replaced the wood and glass. I want to go a different direction.

 

[jbcurt00]

How will you tie pvc stringers to the boat hull and how will you tie the aluminum deck to the sides of the hull?

Both are necessary.

 

[Woodonglass]

What kind of PVC flooring do you have in mind. Where would you use the aluminum?

 

[ricohman]

Would be tough to make aluminum into the shapes of stringers. And fixing them to the hull? I have no idea how you would do that.
I suppose sheet aluminum could be cut to shape and tig welded but this would be a time consuming task. And you can't really shape to fit after the fact.

 

[GA_Boater]

Welcome aboard.

We know you want to build an indestructible boat, we all do. The deck and stringers usually need replacement because of neglect.

Replace the rotted stuff with original type materials for the proper structural strength, poured 2 part foam under deck if it came that way and keep her covered and protected - She will last a long time by taking care of her.

Replacing with PVC and aluminum will last a long time, but the structural strength of the boat will suffer. Good luck on your resto.

 

[Chadomosis]

Yea, I've got lots to figure out it looks like. I have access to cnc machinery, so any custom shapes are no problem. jbcurt00, your question is one I need to figure out. Maybe a clip system or something. I know the stringers are an important part of the structure and I want to do it right. Maybe some clips that are wood and glass to mount aluminum angles and pvc in between. I'm still brainstorming here! I've been looking at the seaboard product and I'm interested. Just gotta figure out the critical structure points.

 

[Chadomosis]

It appears as if the sea rays made in the late 80's are rotting from the inside. Area's that even if you're paying attention, could be overlooked. The previous owners of this one clearly dropped the ball with any kind of structural boat maintenance. Mechanically however, motor, out drive and such, has been very well maintained. Well, I'll post pics and vids of the steps that I take along the way and I supposed if it's bad enough, I might go push it off of the trailer at the junk yard. I'll get pics if that is in fact, how this plays out.

 

[jbcurt00]

Heavier, more expensive and harder to join into a structure that remotely provides the same support the original did.

Sorry to be a doubter, but it sounds like a good way to waste good materials on the wrong application.


There are 50yr old boats, made w plywood and less the perfect fiberglass work, that arent rotten from the inside out.

Use what you like, but, as it was before w better attention to detail, would be more then sufficient.

 

[Chadomosis]

Don't appologize, I certainly appreciate the input. I've seen quite a few people on this sight repairing these boats and the strings are fascinating. I always think outside the box as I'm a natural problem solver trying to make things better. The thing that had me thinking about pvc, was weight. It's so much lighter than plywood and glass and there's no worry about rot. It's the structure strength that I'm not sure of yet.

 

[nateo]

Unless you're considering starting a boat manufacturing business don't waste time on this project unless you've got say $10,000 invested already. I just sold a boat recently that I spent most of last summer on for $800. Had over $6000 in it and probably at least a hundred of hours only to come to conclusion that motor needed overhauled (this is after I removed motor, and rebuilt motor mount, and replaced a bunch of parts). I ended up buying a sea ray made in 2006 and never been happier. The entire floor is glassed/geal coated. Some boats from the 80's just aren't worth the time. Often times folks don't ever finish these major projects. Sell what you can from it, cut your losses, buy something newish and go boating. Working on boats is a fun hobby but boating is more fun.

 

[nateo]

with that being said if you want to watch a youtube video series. This guy does a sea ray floor rebuild. It's fairly interesting and enteraining to watch, will give you a idea of what it takes. Cool part is he does finish the job. His second project is still not finished though (a few years later). Often times people go buy a new boat 3/4ths of the way into the project.

https://www.youtube.com/playlist?list=PL02C318B574CD948D

 

[Chadomosis]

So far, all I've got invested is a few hours of time. It's already got a new 3.0L in it and the out drive appears extremely clean. This guy was a mechanic, not a boat guy. I've got pretty much all of the materials aside from the 2 part foam. I think I've gotta do this...

 

[Woodonglass]

Some vintage fiberglass boats WERE made with aluminum Stringers. None that I know of have ever used PVC. It is NOT a structural product and does NOT play well with Fiberglass Resin. Thinking outside the box IS a good thing IMHO however there are times when the "Tried and True" methods make the most sense. This is one of those times.

 

[Chadomosis]

Upon further inspection, the damage isn't nearly as bad as I thought it was. Stringers are mostly clean and the transom is just fine. It's pretty much only spoiled around the fuel tank.

 

[nateo]

Here's a short insperational video. He gets it done

https://youtu.be/yXCZQzxwFx4

 

[tpenfield]

If you want to do something other than wood, you are best to use a high(er) density foam (Divinycell) and glass over them in a similar fashion as you would with wood stringers. Some higher end center console boats are made this way.

 

[harleyman1975]

The main problem is that when produced new they are mass producing quickly in an effort to make money so the thought of "how do we make it last forever" is not part of the equation. If you encapsulate your wood you will have a 10 year advantage right out of the box!

 

[Chadomosis]

Good vid Nateo. That time lapse sure makes it look easier than it is. After thinking about this, I'm going to stick with tried and true like you all have said. Luckily, the rot hasn't traveled as bad as some of the ones in similar situations. That being said, I'm planning on at the very least, reinforcing what existing and replacing what's crap.

 

[Chadomosis]

In friscoboaters adventure, he mentions a product "pooky". What the heck is pooky? Looks like a liquid nails or epoxy of some kind... Google brings all up kinds of cute crap so I'm curious. Apparently I need it.

 

[tpenfield]

Pooky ???? I thought he was talking about his dog