different type deck?

[jdcoombs]

I'm always lookin' at things in a little bit of a skewed manner, so I started thinking (that's dangerous) about my deck replacement.
Basically, we put in foam, then plywood and fiberglass, right?
Plywood (unless it's teak) will eventually rot and/or delaminate. Even PT, it just takes langer.
Why not foam up to the top of the stringers, put some sort of mechanical fasteners on top of the stringers, then just do a glass build-up?
If a solid substrate is needed, what about something like 18 ga perforated aluminum or some such?
Any comments on that? Has either been done?

 

[gcboat]

Re: different type deck?

First off I wouldn't like to walk on a metal surface after it's been baking in the sun. The "ouch" factor would be way up there.
Secondly, you're not going to find any type of resin to bond to the metal. So you're back to wood for an underlayment. A good coating of resin ( epoxy preferred ) over your ply will give you years of service. Unless you plan on making this a project for your great grandkids to enjoy I'd probably just stick with wood.
Besides, I couldn't imagine how much weight you'd be adding or the added expense of it all.
Nothing saying it can't be done - I just wouldn't want to.

 

[ondarvr]

Re: different type deck?

You can always make it better, faster, lighter...... all it takes is $$$$$$$.


Boats are ready made with about every combination of things you can imagine, it just drives the cost so high few people can afford to buy them.

The floor in one of my boats is made with honeycomb sheets and a layer glass over the top and up the sides a few inches, the whole floor is very light and strong.

 

[jdcoombs]

Re: different type deck?

Mostly the question is about not using a plywood deck at all. Just glass over the foam (after smoothing and levelling). Has that been done?

The suggestion for perf aluminum would just be for a smoothe substrate (between the glass and foam), to make it easier to make the floor flat. Perforated plate because it makes a complete complete bond to resin as it runs thru the holes and provides a mechanical connection. I can get perf aluminum as cheap as PT plywood, which eventually comes apart, and *definitely* cheaper than teak plywood.

But, is it a DUMB idea that wouldn't work well or wouldn't be stiff enough? When I want to try something new, I always look to see if it's being done by others, and there may be a good reason if not. Good sanity check.

 

[DJ]

Re: different type deck?

Mostly the question is about not using a plywood deck at all. Just glass over the foam (after smoothing and levelling). Has that been done?

The suggestion for perf aluminum would just be for a smoothe substrate (between the glass and foam), to make it easier to make the floor flat. Perforated plate because it makes a complete complete bond to resin as it runs thru the holes and provides a mechanical connection. I can get perf aluminum as cheap as PT plywood, which eventually comes apart, and *definitely* cheaper than teak plywood.

But, is it a DUMB idea that wouldn't work well or wouldn't be stiff enough? When I want to try something new, I always look to see if it's being done by others, and there may be a good reason if not. Good sanity check.

An all fiberglass deck would have to be very thick (read heavy). Can it be done? Sure. Many boats that have no wood in them use a product called "Divynicell". It is basically a fiberglass honeycomb board.

 

[ondarvr]

Re: different type deck?

Like DJ said The Fiberglass would need to be thicker to not flex and move under foot, that's where the plywood or other type of core (foam, honycomb, or some type of composite board) comes into play. A thin sheet of aluminum would form a flat surface, but is still very flexible, so more glass would be needed to stiffen it. Pour foam would support the floor for a while, but it's not very strong, so as it starts to break down there will be soft spots in the floor. You can go with heavier pour foam, but the weight and cost go up. While plywood has it's problems, it gets used because it's cheap, readily available, light, easy to work with and lasts a long time (long enough) if used correctly.