I took on a large project of replacing my flooring and swim step in sheets of pre patterned EVA foam flooring. Since many people just need the step done I figured I would post this as a stand alone project. I got the pad off in one piece with some help from a neighbor who had a windshield removal tool. Having the pad in one piece saved a ton of time when making the wood template. It did however leave all of the glue behind. The deck glue was no fun to remove. Using paint thinner and a scraper I finally got it all off and had a smooth gel coat finish.
I used a router around the outside edges of the mats to give a finished look. I used 1/8" wood masonite hardwood to make a template of each piece. Cheap hardwood sheets are a lot cheaper and easier to replace than the flooring material. I then used the template on top of the flooring as a guide to cut the sheets. Then I put the flooring on top of the template and used the wood as a guide for my router around the outsides. First off I'm using a Makita variable speed trim router on this project. I found the smoothest passes came with the speed just above 3. I ended up going with a 1/4" x 1/2" rounding cove bit. I played with a couple of scrap pieces to get the depth and tried both style pieces together to make sure that my plan was sound.
Next up was the smaller pieces.
I cannot say how my flooring will hold up over time, but I would be surprised if it doesn't do well. The supplier is http://www.marinedeckfactory.com.
They are in China. They were great to work with. Answered every question I had and the product was at my door 2 weeks after I ordered it via UPS. My friend also got his product in 2 weeks. They have many color options. Hope this helps some of you guys. They do have a 5 roll minimum which is approximately $350 shipped depending on where you live. Those 5 rolls will do your step and your interior of your boat. Click the link to see the interior project that went with this
My disclaimer is this, I have been installing stereos in boats and upgrading boats for years. I have a lot of tools at my disposal along with a lot of boat interior experience. The rolls don't put themselves in. However with some patience and a good plan going in, it isn't that difficult to do. I definitely think in increased the value of my boat at least 3-5 times what the project cost. I hope this helps some of you guys take the risk and go for it!
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