While prepping our boat for its first outing this year, noticed some soft spots in the floor - it had turned to compost.

I don't even want to know what was fermenting under the fuel tank.

There's something inherently wrong with taking a circular saw to the floor of your boat.

Out come the seat bases.

The floor had the most rot around the ski door. The expansion foam was waterlogged and had to be removed.

The floor is completely removed, as well as the storage areas in the bow, and under the dash.

With the older stringers out, now we start on the new.

Stringers are complete and laid out - next comes the fiberglass...

The stringers are fiberglassed in - next is the mid section of the floor.

As with everything else Each side is convered top/bottom with 1.5 ounce chopped strand mat.

All floor sections have been fitted, and are finally ready for installation. Each section has been filled with 2-part floatation foam - a fun science experiment...

Bow storage areas get fitted next.

Making sure everything is aligned correctly, it gets one last check before being disassembed,fiberglassed, reinstalled and the front section filled with floataion foam.

Seat bases need to be constructed next.

New seat tracks are cut into the side panels, prior to the real side panels going on. Made a little mistake in the assembly as you can see in the previous pic- the end pieces should have been sandwiched in between the side panels. This fixed the mistake, and made for a stronger base. Should have been this way in the first place ;-)

Dry rot....

Using what's left of the old for a template for the new.

The existing upholstery was in good shape, so I reused it over the new seat base.

One side is completely rotted away...

After sandblasting it clean, I fabricated a new section and welded it in.

New floor material is glued and ready to go down.

Getting there - more work and fewer pictures as I get closer to the end...

All back together. You can see the repaired hydraulic pump bracket on the left.

Everything is back, carpet installed, etc

...and my crew is ready to hit the water.

Finally getting ready for a test run at Harrison Lake.