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  1. #1
    Seaman Apprentice
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    Default Floor Project - 1992 Sea Ray 180 Runabout

    1992 Sea Ray 180 Runabout Mercruiser 3.0 Alpha One GenII

    Project: Replace floor due to rotten wood and water logged foam.

    My wife really likes the boat, so that is why I am fixing it. We intend to keep the boat for quite awhile since this is our first boat.

    I purchased this boat earlier this spring with knowing the floor needed to be replaced. I have already repaired the lower unit and put new bellows on the back. I have had the boat on the water multiple times, but I kept finding more and bigger soft spots as the past few months have gone by, so I decided with the high water and most of the rams are closed in my area I would start on the floor.

    I've just begun the process of removing the carpet and started cutting away on the floor to remove the foam.

    I'll probably have some questions as I continue, but for now I'm just working to get the floor out.

    Opinion Question: I'll probably put carpet back in, but my wife and I are undecided on carpet color between (dark gray, light gray or red). We have red accent color throughout the boat (pin stripe on sides and seat cushions). Carpet color was a medium gray color.
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  2. #2
    Petty Officer 1st Class
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Welcome to the forums. I am knee deep in my '93 Sea Ray 200BR with what started as a floor and front stringer repair and turned into a complete rebuild (floor, stringers, and transom). When you start cutting out the wood, the best tools that I have used on mine is a sawz-all (reciprcating saw), 3" Craftsman circular saw, and a Dremel Multi Max tool. Also, be sure to get a good half face cartridge respirator, Tyvek cover-alls, and safety glasses. You can see the Dremel at work in the link in my sig. If nothing else, at least get a sawz-all. I hope that everything goes well and you can get by with just the floor. If you are able to, would you mid posting some good pics of the engine compartment and how it is laid out. All of that was missing when I bought mine. Thanks, Steven
    1987 All Weld flats boat w/115 Evinrude
    1993 Sea Ray 200BR (in pieces)
    1969 Plymouth Road Runner convertible

    1993 Sea Ray 200 BR rebuild thread:
    http://forums.iboats.com/boat-restoration-building-hull-repair/93-sea-ray-200-br-rebuild-stringers-floor-engine-394334.html



    Steven

  3. #3
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Steven,

    Thanks for the welcome and information about the tools. I am currently using a circular saw and a sawz-all for removal. I also found that using a hand dry wall saw works great for taking the foam out in chunks.

    My father and I repaired the floor on his 1970's 18' tri-hull boat (brand unknown) about 15 years ago, so the memories of safety and tools are coming back to me. :-)

    I'd be glad to put up some more pictures for you of the engine area as I have not started in that area yet. I'll be able to get those pictures taken later this afternoon and put up this evening. I can probably get you some basic dimensions of the area.

    The transom looks to be in good shape and the motor works fairly well, but it tends to to idle a bit on the low RPM side and then it dies. If RPMs are below 600 when idling its just a matter of time for it to kill itself, so I'll look at the carb and try some engine cleaner. I may also bump up the idle RPM to 700 to 800, but not exceed 800.

    Thanks,

    Jerry

  4. #4
    Seaman -DannyBoy-'s Avatar
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    I'm finding the high water to be a big PITA here in Iowa as well but like you, I'm using the time away from the water to get some stuff done. Good luck with your project!

  5. #5
    Moderator ezmobee's Avatar
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    As a previous owner of navy carpet in my last boat....let me cast my vote for light gray as your new carpet color. Will hide dirt MUCH better than your other choices. My navy carpet was a nightmare. I went with marine vinyl on my current boat.
    1976 18' Starcraft SuperSport 90HP Evinrude
    Restoration thread http://forums.iboats.com/boat-restoration-building-hull-repair/18-starcraft-supersport-restoration-357767.html
    1966 16' Starcraft Jupiter 85HP Johnson
    Restoration thread http://forums.iboats.com/starcraft-boats/ezmobees-1966-jupiter-338633.html sold

  6. #6
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    ezmobee,

    Thanks for the vote! I appreciate it very much.

    Jerry

  7. #7
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    -DannyBoy- Thanks! I hope you get your projects done as well.

  8. #8
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Steven,

    Here are some links to pictures of the engine compartment. I have the two swivel captain chairs with the bench seating in back for my boat's seating arrangement. I folded back the top laying bench / deck so you could see the entire compartment area.

    Full Quality pics can be found at
    http://www.jkboss.us/boat/pics/floor...mpartment.html

    It is a very basic page, but the pictures are great. The site may be a bit slow so please be patient. :-)
    Last edited by jerrybossard; July 7th, 2010 at 04:41 PM. Reason: Forgot to add the link in.

  9. #9
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Here are the pictures of the engine compartment if the link is too slow for you.
    Attached Images Attached Images

  10. #10
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Here is the second set of pictures for the engine compartment. Hope those help.

    Thanks,

    Jerry
    Attached Images Attached Images

  11. #11
    Lieutenant Junior Grade Wingedwheel's Avatar
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Another great tool that I've used to get all the rot out is the Harbor Frieght Multi-purpose tool($35) with the 3/4 round blade. It gets in tight spots that nothing else can get to.
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    The dictionary is the only place that success comes before work.

  12. #12
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    WingedWheel,

    Thanks for the information.

    Jerry

  13. #13
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Jerry,

    Thanks for the pics of the engine compartment. That kinda gives me an idea of what to do when I go back together with the interior. It will all have to be from scratch. As for your boat, take a good look at the wood in the transom between the outer gel coat and inner layer of glass and make sure it is not on its way out the hole. All of the screw holes that the factory used to secure things to the floor, are all avenues for water to get under the floor and outside of the stringers. Also, be sure to check your stringers good as well. There are screws that secure the fuel tank brackets there also. If you have any questions as to what the interior structure of your boat looks like, let me know or check my rebuild link in my sig. Here are some pics from my boat that you will want to check real good. Mine is a 1993 Sea Ray 200BR. Thanks, Steven

    Starboard transom under floor. There is no glass or anything over this wood and it is rotten:


    This is where the unprotected wood is located. Look at the area at back of boat next to stringer. Same pic as above:


    Starboard side of the gimble housing between the outer transom gel coat and the inner transom fiberglass where the exhaust exits (inside the red lines). The wood is almost dust:


    Port side of the gimble housing between the outer transom gel coat and the inner transom fiberglass where the exhaust exits (inside the red lines). This wood is almost dust:
    1987 All Weld flats boat w/115 Evinrude
    1993 Sea Ray 200BR (in pieces)
    1969 Plymouth Road Runner convertible

    1993 Sea Ray 200 BR rebuild thread:
    http://forums.iboats.com/showthread.php?t=394334



    Steven

  14. #14
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    This is the circular saw that I am using. Works good when making shallow/delicate cuts. Thanks, Steven

    http://www.craftsman.com/shc/s/p_101...2_00910872000P
    1987 All Weld flats boat w/115 Evinrude
    1993 Sea Ray 200BR (in pieces)
    1969 Plymouth Road Runner convertible

    1993 Sea Ray 200 BR rebuild thread:
    http://forums.iboats.com/showthread.php?t=394334



    Steven

  15. #15

    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    As the new owner of a 1989 Sea Ray 180, I am also getting ready to undertake this same project. It seems that my floors are all soft and I am finding several pieces of rotten wood in the bilge each time I take it out.

    Please keep us informed (lots of pictures) as your renovation progresses. I need all of the help that I can get. Any helping hints that you can provide would be greatly appreciated.

    Rodney

  16. #16
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Steven,

    Thanks for the heads up about the transom and the circular saw. I'll be looking at the transom later this afternoon. As you can see from my pics I've not made it to the engine compartment just yet, but will be there by hopefully end of day on Friday.

    What was the size of your original stingers? I have not officially measured mine yet, but they appear to be either a 1 x 8 or something close to that. It also appears the wood may have been plywood and not a 1 x anything. Just curious if you knew what your originals were.

    Do you know what size of stingers you'll use as replacements... 1 x 6, 1 x 8 or plywood? Do you plan on using treated lumber or regular lumber and then glass over for the stingers?

    Did you decide to replace your transom? If so, what did you use for wood? Do you have any more pics of your transom?

    Is it possible to use treated lumber and not glass in the stingers? My local marine shop said they used MDO board for the replacement floor so did does not need to be glassed? Any opinions on the MDO would be great.

    Thanks,

    Jerry

  17. #17
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Rodney,

    I hope you plan on spending quite a few hours/days with your boat to repair the floor. It may look easy... but I kid you not... it is work. I would suggest finding out what your local marine shop would charge you to repair it and ask how long it would take. Once they give you a time frame you'll want to add about 2 to 3 weeks to it, unless you have 2 weeks of full days to work on it.

    There are a lot of helpful hints from other restoration threads, the main thing is to be patient; one wrong move can send the saw through the hull and then you just have a whole new problem. The tools mention by myself and Steven (69rrvert) are good suggestions and will make thing go a bit smoother. I would also suggest finding a long 2 x 4 and a 18" to 36" pry bar to help with the foam removal. Even with the foam cut, it can still be a pain because of the extra weight from the water log and it may have also bonded with the glass. It should not have bonded to the hull but definitely to the stingers and other wood areas.

    You'll obviously have to replace the carpet and I would suggest looking at prices online. I'm not sure how much you will need but there may be some other threads to help with the amount of carpet needed.

    I'll be updating this thread as time continues and also be sure to check out others.

    Thanks,

    Jerry

  18. #18
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    What was the size of your original stingers?
    As best I can tell, they were 3/4" plywood. I am still undecided what to go back with because I will have to splice the plywood if I use it. Whatever I decide, it will probably be marine grade and fiberglassed.

    Did you decide to replace your transom? If so, what did you use for wood? Do you have any more pics of your transom?
    I have not made it the transom yet. I still need to get the inner and outer gimble houseing off and mother nature is not allowing that right now. Nothing but rain past few days and the forecast for the weekend is no better. I will use 2 peices of 3/4" marine ply laminated together for the transom and glass it in.

    Is it possible to use treated lumber and not glass in the stingers?
    If you are planning to keep the boat, I would not take the chance of not glassing them. I plan on this being a one shot job and will definately glass over the stringers. Scan through the thread that Ooops has going on his rebuild and also the rebuild thread that friscoboater has on his boat. They both good threads with a ton of priceless information in that thread. Here is the link to the threads. Thanks, Steven

    Ooops rebuild thread:
    http://forums.iboats.com/boat-restoration-building-hull-repair/hull-extension-progress-pics-234392.html

    Friscoboater's rebuild thread:
    http://forums.iboats.com/boat-restoration-building-hull-repair/81-glastron-sx-190-transom-engine-pics-galore-update-11-8-a-358277.html
    1987 All Weld flats boat w/115 Evinrude
    1993 Sea Ray 200BR (in pieces)
    1969 Plymouth Road Runner convertible

    1993 Sea Ray 200 BR rebuild thread:
    http://forums.iboats.com/showthread.php?t=394334



    Steven

  19. #19
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    I called a fiberglass shop and got a rough estimate on mine. They told me around $4500.00 for a turn key transon, stringer, and floor replacement. As for the carpet, there is no way that I will go back with it. My opinion is that all carpet is good for is holding moisture in the floor. Bad idea in my opinion. I'll probably glass mine in and then coat with something like friscobaoter did his. I may use a snap in carpet but nothing perminent. Thanks, Steven
    1987 All Weld flats boat w/115 Evinrude
    1993 Sea Ray 200BR (in pieces)
    1969 Plymouth Road Runner convertible

    1993 Sea Ray 200 BR rebuild thread:
    http://forums.iboats.com/showthread.php?t=394334



    Steven

  20. #20
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Quote Originally Posted by 69rrvert View Post
    I called a fiberglass shop and got a rough estimate on mine. They told me around $4500.00 for a turn key transon, stringer, and floor replacement. As for the carpet, there is no way that I will go back with it. My opinion is that all carpet is good for is holding moisture in the floor. Bad idea in my opinion. I'll probably glass mine in and then coat with something like friscobaoter did his. I may use a snap in carpet but nothing perminent. Thanks, Steven
    Steven,

    Hmmm... Now I'm really debating about the carpet idea on the deck. I'll have to put carpet in for the back seat, side pocket area and the bottom area by the front seats. I've ripped out all the carpet in the boat. So either way I'll have to put carpet in... but I've definitely got something to think about.

    Thanks for the opinion.

    Jerry

  21. #21
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Is the foam beneath the deck for both flotation and structure or just for flotation? I'm debating on picking up a "pink" foam board from Home Depot and placing it in the bottom sides and then using the AeroMarine two part expanding foam to cover the pink foam. Thoughts?? If it is for structure should I use 4# or 8# two part expanding foam vs 2#?

    Here is what I found at AeroMarine:
    "Q. Is this foam compatible with styrofoam?
    A. Yes - it will not "eat" or dissolve styrofoam. If you have a large cavity to fill, it can be worthwhile to put some chunks of styrofoam in the cavity to save foam."

    I'm curious if the pink foam will be good enough if the foam is used for structural purposes.

    Thanks,

    Jerry
    Last edited by jerrybossard; July 9th, 2010 at 02:19 AM. Reason: missed a word.

  22. #22
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Jerry,

    Check out the link to friscoboaters thread (post 968) that I posted in a previous reply. He used the pink foam board on the sides of his boat and then covered that with the expanding pour in foam. Thanks, Steven
    1987 All Weld flats boat w/115 Evinrude
    1993 Sea Ray 200BR (in pieces)
    1969 Plymouth Road Runner convertible

    1993 Sea Ray 200 BR rebuild thread:
    http://forums.iboats.com/showthread.php?t=394334



    Steven

  23. #23
    Moderator ezmobee's Avatar
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    On a SeaRay, I highly doubt the foam is structural. The sheet foam you're considering is a great alternative.
    1976 18' Starcraft SuperSport 90HP Evinrude
    Restoration thread http://forums.iboats.com/showthread.php?t=357767
    1966 16' Starcraft Jupiter 85HP Johnson
    Restoration thread http://forums.iboats.com/showthread.php?t=338633 sold

  24. #24

    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    new to the board and beginning the same repairs that you fellow Sea Ray owners are doing. '89 Sea Ray 200 BR. Jerrybosard your 180 is the first Sea Ray I've seen in the older models that has the same interior lay out as mine. Mine also has two captains chairs with the bench seat across back with built in storage/coller underneath. Very large sun pad on top. The layout and room of this boat is the only reason I am going to attempt a restoration. I am looking for some pics of how the floor section over the gas tank is supposed to be supported. Mine was rigged together and I would like to know the right way to put it back.

  25. #25
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    Default Re: Floor Project - 1992 Sea Ray 180 Runabout

    Quote Originally Posted by ezmobee View Post
    On a SeaRay, I highly doubt the foam is structural. The sheet foam you're considering is a great alternative.
    Ezmobee,

    Thanks for the confirmation on the foam. I've had another marine mech say that it gives more rigidity for the hull and floor, but mostly for flotation and not necessarily for structure.

    Thanks for the info!

    Jerry

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