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Author Topic:   Replacing soft Outrage floor...Help/Advise
Outrage18 posted 09-26-2001 10:40 PM ET (US)   Profile for Outrage18   Send Email to Outrage18  
I need input from the members of this board on what/how to rip my current floor out and then replace the rotten plywood with new and put it back in place.
I have a guy quote me about $3K to do it.
I obviously want to spend less.
What would BW charge for a new one? Do they even offer that?

Help! Thanks!

lpaton posted 09-27-2001 07:56 AM ET (US)     Profile for lpaton  Send Email to lpaton     
Search the posts. All the information is there. Good luck.
jimh posted 09-27-2001 09:32 AM ET (US)     Profile for jimh  Send Email to jimh     
Can you clarify a couple of things?

What exactly is to be repaired? Just the removeable floor section? The entire cockpit liner? What size boat?

If the repair is just the removeable section, I would think you could accomplish this yourself, although it might be an ugly job to unbond the old wood, grind down to the laminated and rebond new wood.

LarrySherman posted 09-27-2001 11:58 AM ET (US)     Profile for LarrySherman  Send Email to LarrySherman     
Here is a responce to a hatch rebuild. Will work just as well for a floor. Its a big job, and you need space and help to get it done.

Outrage18 posted 09-27-2001 03:37 PM ET (US)     Profile for Outrage18  Send Email to Outrage18     

I need to replace the removable section of the floor, it is sometimes called the gas tank cover(large rectangle piece.)....The boat is an Outrage 18.

any help..?


tlynch posted 09-27-2001 06:27 PM ET (US)     Profile for tlynch  Send Email to tlynch     
Hello all,

On the subject of a soft floor in an outrage 18:

This past weekend a placed my weight on the foward port section of deck and heard what sounded like air escaping and a slightly wet hiss. - and the panel went from solid to soft. The two aft panels on either side of the Gas Tank Cover are soft as well.

For clarification please take a look at this annotated photo:

Is their plywood under the non-skid or is their foam immediately underneath? Is their any void or is the boat solid foam? How would you recommend going about fixing this? How important is it to fix?

Thanks in advance,
Todd Lynch

acseatsri posted 09-27-2001 08:00 PM ET (US)     Profile for acseatsri  Send Email to acseatsri     
I'm curious, what kind of material are the screws going into that hold down the section that you took out? Mine's not soft, but there are a couple of missing screws that need replacing. I'm waiting for spring to let any moisture out before attempting any repair. I also have a few holes that used to hold a RPS in place that need filling as well. I was thinking of routing them out as someone described and then filling them with West System.
eric_from_MD posted 09-28-2001 11:03 AM ET (US)     Profile for eric_from_MD  Send Email to eric_from_MD     
acseatsri- That's actually a pic of my guardian gutted. Around the perimiter where the screws go to hold down the floor it appeared to have some wood behind the glass. I don't know how much and don't remember seeing it on the Whaler drawing that is supposed to locate the wood in the hull. All I know is that wood was comming out with some of the screws. If you are going to use epoxy try to dry the area out first, I don't think epoxy will stick to the wet surface. Mine is a CPD hull and recreational hull may be slightly different, but I am not exactly sure in what areas. Eric
tlynch posted 09-28-2001 05:58 PM ET (US)     Profile for tlynch  Send Email to tlynch     

I just used your pics to show where my floor is soft, hope you don't mind. Do you have any idea what is under the fiberglass in those areas? Plywood? Foam? They are soft enough so when you step on them you think, "oh, this is soft!". Any idea on how to fix it, I am planning on doing a lot of work this winter.

Thanks again,
Todd Lynch

eric_from_MD posted 09-28-2001 06:41 PM ET (US)     Profile for eric_from_MD  Send Email to eric_from_MD     
Todd - No, I don't mind at all. I think that foam is directly under most of that area but have no proof. The only wood under the floor should be the wood that is refered to in the (wood locating) drawing from Whaler. I know mine is also soft but only toward the stern were the wood is located. I would think if it's rooted wood underneath the floor could be cut out in this area and a new epoxy soaked/encapsulated piece could be put back in. Of course the the fiberglass floor would have to be epoxy and faired back into place. If it is foam underneath that is another story. Is the floor buckled (foam seperated from glass) or is it flat and goes down below the plane of the floor when you step on it. Gotta run, will check back Sat. You may want to try to get DIVE1's input, he seems to have extensive knowledge of these hulls. Good luck, and research before you react. Eric
lhg posted 09-28-2001 06:46 PM ET (US)     Profile for lhg    
Regarding the OUTRAGE floors, the gas tank and other screwed down covers have 3/4" plywood under the glass. The "hull" part of the floor only has foam under it.
tlynch posted 10-08-2001 03:03 PM ET (US)     Profile for tlynch  Send Email to tlynch     

I took a look at my floor this weekend, it actually does not seem that the foam is soft rather that the fiberglass has delaminated. That had not crossed my mind thanks. I know that there is a post somewhere describing how to get epoxy in there and put sand bags on it etc. I'll find it. Thanks for your help.


Outrage18 posted 10-09-2001 11:24 AM ET (US)     Profile for Outrage18  Send Email to Outrage18     
Thanks team!
One more question...
Once I rebuild the floor, how should I attach a leaning post? should I bolt it through while I have the floor out?

How are they attached usually?

Thanks in advanced.


lhg posted 10-09-2001 06:24 PM ET (US)     Profile for lhg    
Regarding installation of equipment on the gas tank covers, BW has always recommended using screws (usually #14's) that penetrate the floor (and into the the 3/4" plywood, no more than 1". Through bolting not recommended.

Do not install seats or consoles into a Whaler floor where there is no wood/whalerboard backing. You can delaminate the floor from the foam.

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