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Old 09-05-2018, 08:59 AM
hardycm's Avatar
hardycm hardycm is offline
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Join Date: Aug 2004
Boat: ,88 Prostar 190
Location: Cincinnati
Posts: 88
1988 PS 190 floor replacement?

After 30 years, the floor board behind the engine cover is finally getting too soft to trust. I've seen some posts about supporting it with aluminum angle iron and have done a similar thing. However the board is now so spongy that unless you stand on the brace, it will give. I'd like to replace it with something fresh and am looking for suggestions. What have others done? Marine plywood? (I hate to use wood), plastic panel? Other ideas?

Also any pointers on getting the carpet off without destroying it? I don't want this "simple" repair to turn into re-carpeting the entire boat!

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Old 09-05-2018, 10:32 AM
Miss Rita's Avatar
Miss Rita Miss Rita is offline
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Join Date: Jul 2009
Boat: 1992 ProStar 205, 1991 Ski Pro
Location: Black Hills
Posts: 1,491
You don't need marine plywood. From Google:

Marine-grade plywood, often simply called marine plywood, is not what it's often claimed to be. That is, it's not waterproof. Since it's not treated with chemicals it is not rot resistant. However, it is a good-quality, hardwood plywood made with waterproof glue. Better grades also tend to be lightweight, strong, and virtually free of defects.
Treated or even regular 3/4" plywood from your local store will work fine. You'll want to encapsulate it with a couple of coats of epoxy resin to make it waterproof. The biggest problem will be trying to reuse your carpet, I'm skeptical that you can remove it without destroying it.

You can use Starboard, which is HDPE. Being plastic, it will never rot. It will be expensive, and I don't believe it will be as stiff as plywood.

If it was my boat I'd go with a nice piece of treated plywood.

Last edited by Miss Rita; 09-05-2018 at 10:57 AM.
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Old 09-05-2018, 12:12 PM
88 PS190 88 PS190 is offline
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Join Date: Aug 2005
Boat: 1988 MC Prostar 190, 351 Ford
Location: Midwest
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My 88's rear's floor is soft too - its also kind of thin. My 94 had the aluminum honeycomb and its been replaced with a ~1" thick piece of starboard - which is a heavy heavy part. I'd replace that with wood in a second if I had matching carpet.

The 88's I will probably do with plywood, painted with thin epoxy and vacuum bagged between two layers of plastic sheeting to draw it into the wood.
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Old 09-18-2018, 11:26 PM
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jayR jayR is offline
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Join Date: Sep 2016
Boat: 1988 prostar 190
Location: Boston
Posts: 187
When I redid my boat last year (still working thru it) I just used plywood that i epoxied... I assume it will last a good long time. One thing I did do was on the piece behind the motor box I remade it into 3 pieces.. thinking I wanted to be able to lift the floor hatch to be able to adjust prop shaft drip rate or at least check it with out removing seat and engine cover.
So i have one small piece maybe 5 inches wide that I just screw engine hinges to, the next one fits in between that piece and where seat begins. there is a third piece under the seat. the only piece i have screwed down is the one the engine cover is attached to. Its worked out great. you can sort of see the breaks in the 1st image along with improved rear seat storage. In the 2nd pic you can see how I reinforced the panels by using strips of ply mounted on end. these were epoxied as well and glued/screwed in. the reinforcement are probably overkill as its not much of a span and its probably fine if they bow a little.
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