Pontoon Sub-floor/Flooring Suggestions....

[SolomonMan]

All,
I recently purchased a project pontoon (1990 Sun tracker Party Barge) with new upholstery and was curious what materials are suggested to replace the main decking as mine now has 3/4 inch plywood and carpet.....Looking to replace with new floor (wood, metal, or other?) and new carpet. From talking with the two owners (original and second) this will be the pontoons second floor. The project will begin in late winter/early spring so I am getting a head start on direction of the project.

My background, with family business is with construction and flooring but am an engineer by trade, so looking to see if there is something that will be more durable...suggestions?

Also I am in the Northwest Ohio for what its worth.

Thanks,
Chris

 

[OK Toon]

Re: Pontoon Sub-floor/Flooring Suggestions....

7-layer marine grade plywood for the deck.

 

[MH Hawker]

Re: Pontoon Sub-floor/Flooring Suggestions....

Ask what the second floor was, and i suspect you will find out it was cheeped out on and not marine grade plywood. That normally last 20 years.

 

[icyveins]

Re: Pontoon Sub-floor/Flooring Suggestions....

I am really happy with the 7-ply marine ply 3/4 4-8 I purchased from Menards, it was special order from wisconsiin I think, burlough hardwoods.
it was 65-70$ a sheet and really nice stuff. I topped it off with marine vinyl. very happy with the results

 

[The Woo Woo Kid]

Re: Pontoon Sub-floor/Flooring Suggestions....

^^^^^^That's what I would do,,, Use vinyl that is.

 

[SolomonMan]

Re: Pontoon Sub-floor/Flooring Suggestions....

All,
Thanks for the responses!

I believe the last owner only used 3/4 standard Plywood but there is actual argument, at least in a few areas whether it was even 3/4.

I know of Marine Plywood and have used it in another restoration (1959 Lonestar Monterrey-My late dads). I liked it and it was a good product and due to the age and nature of the restoration it was a must do.

We have a Plywood Specialty shop (Toledo Plywood) locally in my area that I have done a considerable amount of business with that suggested something slightly different but after everyone's input I am confident I am going to use Marine.

I will give you the run down of what he said for prosperity(Please comment)...He mentioned that the big issue with plywood and boats is that amount of voids between the layers of plywood. Evidently Marine has no voids or very close to no voids while standard plywood has a large percentage. This allows water absorption/rot etc. to occur.

The guy said that he has a product that he stocks that is close in the amount of voids as Marine but without the Marine stamping. Evidently we have a large wood boat building club in the Toledo area and he keeps it in stock for them. Evidently its "good" both sides for boat building and finishing. The cost is close to half the cost of Marine (~$45-50 a sheet)

I am thinking that based on the amount (half dozen sheets) that marine will be my best bet but am still curious as the price is considerable won't aluminum sheets/some form of new plastics decking material be close as well?...I am thinking outside the box here but like I said marine ply is the way I see myself going on this project.

I will also, like I did in my last restoration, use marine paint and seal the wood up. We see marine paint up here in Lake Erie region all the time in Restore shops/craigslist etc. and I am going to cover it up with carpet but I may use a vinyl/carpet combination to spruce the layout of the pontoon up and also make cleanup etc. easier.

I am curious of opinions on what I was told by the plywood shop as I have been kicking around a while a small project of building a small boat to use with a bunch of my lower horsepower classic Outboards.

Thanks again for the help,
Chris

 

[OK Toon]

Re: Pontoon Sub-floor/Flooring Suggestions....

Just my $.02 but if you going to go through the trouble of replacing out the deck (removing all furniture, rails and helm), then doing it right the first time just seems the best choice and that would be 7-ply marine grade plywood. You could try the other stuff if you don't mind having to do it again and still spending the big bucks if the other stuff doesn't work unless you just plan to keep this project boat for a short amount of time. I hate to do projects twice and I've learned over the years there is no such thing as a cheaper alternative.

 

[fishrdan]

Re: Pontoon Sub-floor/Flooring Suggestions....

"Marine plywood" is a loose term and could be anything from Lloyds of London ($$$) BS1088 certified okume/meranti plywood, untreated (will rot) dougfir plywood, regular plywood (lots of voids and knots) that's treated for use in marine applications, or what I think what you're looking for,,, pontoon decking.

If you are planning to keep the boat for more than 5 years, you'll want to use CCA treated plywood like pontoon decking or PlyDek XL NOT ACQ treated (green) plywood that will eat your aluminum boat, the stuff that's available at most home improvement stores.

 

[SolomonMan]

Re: Pontoon Sub-floor/Flooring Suggestions....

All,
Thanks for the clarifications on Marine Plywood.

I will look into CCA wood/PlyDek XL....It appears Gander mountain carries it....which is already considerably cheaper then my other source.

I appreciate all the help,
Chris

 

[rocket rich]

Re: Pontoon Sub-floor/Flooring Suggestions....

can I screw the new plywood to the existing floor as it is coming apart on the top layer or 2 in high use area?? it's a 16 foot Rocket Craft old but still working with no furniture ???? PM ME if necessary

 

[OK Toon]

Re: Pontoon Sub-floor/Flooring Suggestions....

Marine grade plywood is heavy. So I would not recommend screwing it to your existing floor. Since there is no furniture, it would be much easier to remove the decking.

 

[2DFish]

Re: Pontoon Sub-floor/Flooring Suggestions....

Personally, I would not use ACQ (alkaline copper quaternary) plywood. ACQ lumber is about 500% more corrosive to steel than CCA treated lumber, which is why building code changed a few years ago to require double galvanized, stainless or coated fasteners when in contact with ACQ. I have to believe that galvanic corrosion is an issue between ACQ and aluminum, too. I'd go with the PlyDek.

I wouldn't fasten to the old decking. As the old deck continues to deteriorate, the new deck will become loose and pop fasteners.

Finally, unless you're talking about a kiln-dried product, make sure the material you use is dry enough to paint. I typically wait at least several months before painting any kind of treated lumber.

 

[SolomonMan]

Re: Pontoon Sub-floor/Flooring Suggestions....

All,
This is Chris, original poster....

I would and plan to remove my original decking as its just another source for water to be absorbed.

Just weighing the boat down some more.

Most Pontoons I have read about replacing the deck and have seen will unbolt/unscrew. So it should not be to big of deal either way.

I assume that all bolt fasteners (railing, seating, etc.) should be replaced with stainless if possible....

I noticed my deck is screwed down (large screws)... what should I use to screw the deck down? I am guessing my screws will not be re-useable looking at many of the heads.

Thanks
Chris

 

[MH Hawker]

Re: Pontoon Sub-floor/Flooring Suggestions....

can I screw the new plywood to the existing floor as it is coming apart on the top layer or 2 in high use area?? it's a 16 foot Rocket Craft old but still working with no furniture ???? PM ME if necessary

You should start your own thread to keep it from confusing others. That being said remove the old deck and replace with new wood.

 

[Bamaman1]

Re: Pontoon Sub-floor/Flooring Suggestions....

My old pontoon boat is a 1985 model, and its original marine plywood is still good. The last piece on the rear was replaced once with sealed and painted regular plywood, and it only lasted 5 years. Real marine plywood is the only thing to use on a pontoon boat. And it should be put down with stainless hardware.

See Pontoonstuff.com for a stainless steel hardware kit to replace your decking. They're much cheaper on stainless hardware than you can find locally, i.e. Fastenal.

And when you're replacing any carpet, either replace it with marine vinyl (also available at above) or a really good quality marine carpet. Either must have the correct mastic (glue) and be rolled down with a 100 lb. vinyl floor roller. There are many, many carpet and vinyl glues, but not all are for marine use. The places that sell carpet and vinyl online will also have the correct mastics for sale.

 

[SolomonMan]

Re: Pontoon Sub-floor/Flooring Suggestions....

All,
On the glue...I second the use of proper glues....Speaking from almost 20 years of flooring installation experience and growing up in a "flooring" family (3rd generation)...more good projects are ruined by poor glue.

I was surprised not to find the glue that I commonly used to use for porches not being used on pontoons. This glue was solvent base, not to be used in doors and not be used by any flames etc. It is the same price as the glues I have seen for Pontoons which is about the norm for a good glue.

This porch stuff did not come off with water. Mineral spirits and a lot of elbow grease would knock it down but it was still there.

The only reason I may not use it is due to the fact that 15 years later removal is more than difficult - 8 inch strips or electric stripper.

Thanks
Chris