We are excited because we finally finished replacing the cockpit floor of our sailboat. This was a BIG project that required a cascade of smaller things to be completed first. We replaced the cockpit teak wood flooring (which was beyond saving and leaking) and put in PlasDeck, which is a synthetic teak substitute.
I will admit that this project was not much fun. It was a highly detailed, you-only-have-one-shot kind of project, and we had to work quickly as the glue dries so fast (under 15 minutes!). But, we are pleased with the finished result and are excited to have access and use of the cockpit again!
First, we prepped the floor and our new table pedestal (which Kirby built, then we fiberglassed, sealed and painted) where the table is mounted; this new pedestal will also gives us secure space to put a small trash can and (vintage) playmate cooler as well as an important toe rail/toe stop while the boat is heeling underway. We plan to put 3M non-skid tape on the sides as well.
After the floor sat in the sun for a couple of hours, it was flat and ready for installation. We had to prep the cockpit surface by sanding it to remove any large bumps and then cleaning it thoroughly with denatured alcohol.
Then we dry fit and traced each piece before gluing them to the seats and to the floor. You have to work in sections, and quickly, as the glue sets up in 15 minutes, also making it nearly impossible to wipe off or clean up if you aren’t cleaning as you go along.
THE FINISHED PRODUCT!
TIPS: If you’re doing this job yourself, spend extra time up front on the template because once it’s cut, it’s cut! Make sure you have ALL of the materials ready before you start any work (take an inventory and use the checklist provided by the installation guide), and have dozens of clean WHITE rags with at least a gallon of denatured alcohol for spills and any glue cleanup. You can see a few videos of this project, here: SANDING, CLEANING, PREPPING FOR GLUE
FINAL TIP: Prepare to work quickly and swear (a lot).