Thread: Need help for replacing floor in my aluminum boat

Make sure the seam is on a rib. Seam should run down the center of the rib. Then rivet it down. If not then other option is weld it with maybe a backer plate underneath the two pieces at the seam.


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I think the hardest part about this project is cutting the aluminum to the correct size. Having to position the joints over a rib is causing me to make an additional cut or two. Anyone know a good way to cut aluminum plate? My jig saw is slow.

Cut with an angle grinder.
Dont expect anything that should be square/uniform to be so.

1/4” is very thick for flooring. Have you considered the added weight? Most boat floors are 1/8” or less thick.

I thought about the weight and it is a concern but the plywood floor was very heavy also (apparently water logged from time to time). In addition, I am tired of working with a bad floor. My boat is slightly over 16 ft. I run a 25 HP mercury (don't remember how old it is) and it pushes me around fairly well. On top of this, I have gained a few ounces and I don't want the floor to warp or bend under the weight of all the fish I have eaten. I see retirement around the corner and I want to get my boat in shape so I don't have to work on it all the time.

It's been parked a few years so I will have to go through everything. Next up is to repair the bunks on the trailer and get the trailer back in shape.

I have cut it with a skill saw before....only lower blade just enough to cut thru the aluminum ....if aluminum is quarter inch....set blade at three eights.

I had not considered a skill saw for this. Thanks.

Originally Posted by "G"

I have cut it with a skill saw before....only lower blade just enough to cut thru the aluminum ....if aluminum is quarter inch....set blade at three eights.

Like "G" said, a skill saw works well. We have cut pole barn metal with skill saws with the blade turned backwards. Just wear some eye and hearing protection.