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View Full Version : 96 honeycomb floor...she gone


mgs96ps
10-16-2013, 11:54 PM
I have started my first off season project....which is to remove the aluminum honeycomb floor out of my 96 prostar 190. After combing the scrap yard at work, I found a one inch thick piece of HDPE plastic big enough to cover the front section. I also found a 5 foot long, 12 inch strip of HDPE plastic which I will used to construct the back floor. The back floor will be split into (3) sections....the front section to hold dog house hinges, the middle section with quick access to drive shaft/packing nut and the aft section with quick access to rudder (after removing seat).

If post has interest, I will continue to attach pictures. Here are a few to start.

JMLVMI
10-17-2013, 12:16 AM
What's the weight difference?

mgs96ps
10-17-2013, 12:24 AM
What's the weight difference?

Yes...there is a weight difference. I do not have aft section yet, but I will try to get front section difference. HDPE is no doubt heavier.

I am working out to make up the difference.:D

mikeg205
10-17-2013, 07:12 AM
Yes...there is a weight difference. I do not have aft section yet, but I will try to get front section difference. HDPE is no doubt heavier.

I am working out to make up the difference.:D

too funny - but awesome.. :)

Bouyhead
10-17-2013, 07:24 AM
Nice work! I'm interested in seeing the three piece aft section. When I did the floorboards on my 96' I used plastic Starboard and went with a two piece aft section, one for the doghouse hinges, and the other section removable for shaft/packing nut, and rudder access. I wouldn't sweat the weight, Starboard stuff weighs a ton compared to honeycomb aluminum, but no one noticed the difference.

mgs96ps
10-17-2013, 09:26 AM
Nice work! I'm interested in seeing the three piece aft section. When I did the floorboards on my 96' I used plastic Starboard and went with a two piece aft section, one for the doghouse hinges, and the other section removable for shaft/packing nut, and rudder access. I wouldn't sweat the weight, Starboard stuff weighs a ton compared to honeycomb aluminum, but no one noticed the difference.

bouyhead,

I hear you on the 2 piece aft floor section...my problem is that I only have 12" x 60" HDPE. I looked at pricing out a sheet big enough; but it is expensive stuff and I found what I have for free. Still engineering something to work for aft floor...my boat is an hour from home, so finished product will take a while.

BTW - how wide, (front to back), did you make piece that holds hinges for dog house?

markmcfarland
10-17-2013, 11:10 AM
Probably a stupid question, but why would you need to replace the aluminum floor?

drschemel
10-17-2013, 11:20 AM
Yes...there is a weight difference. I do not have aft section yet, but I will try to get front section difference. HDPE is no doubt heavier.

I am working out to make up the difference.:D

So, you add like 1200# balast to get a better wake but worried about 50# difference in flooring material?

mgs96ps
10-17-2013, 11:32 AM
Probably a stupid question, but why would you need to replace the aluminum floor?

Honeycomb is de-laminating, floor is noisy, spongy in areas and aft section has almost cracked into half trying to support weight of dog house (it was already flipped 180 degrees to re-support weight). Water really had nothing to do with it failing after 17 years...it just does not hold up forever since much it is not supported underneath. Material spans across stringers. Lastly, I would like to make checking shaft/packing nut more accessible as well to greasing zerks on rudder, currently you need to remove dog house just to do any work back there.

mgs96ps
10-17-2013, 11:40 AM
So, you add like 1200# balast to get a better wake but worried about 50# difference in flooring material?

I hear ya...however I would never add that much in my boat. We all now that 190's are really ski boats...and the purist may be concerned about the weight. I am a skier first and recognize that 20LBS off the body will go way further than adding 20LBS in the floor.:D

DooSPX
10-17-2013, 11:41 AM
I have thought about making my aft section of floor 2 pieces or one large access port in my 91. It is just now starting to get just a little soft.

Bouyhead
10-17-2013, 08:27 PM
bouyhead,

I hear you on the 2 piece aft floor section...my problem is that I only have 12" x 60" HDPE. I looked at pricing out a sheet big enough; but it is expensive stuff and I found what I have for free. Still engineering something to work for aft floor...my boat is an hour from home, so finished product will take a while.

BTW - how wide, (front to back), did you make piece that holds hinges for dog house?

Had to measure in the dark, but it looks like 7 1/4" I thought the wider the better. Pretty sure the front section was touching the exhaust hoses. Rear floorboard was 29 1/2" and tucks under the carpeted panel that conceals the fuel tank.

Jeffer
10-20-2013, 01:01 PM
You can pick up doghouse hinges with removable hingepins, which makes pulling the motor cover out when you need to REALLY easy. Worth putting them in if you're pulling the floor anyway, IMO.

mikeg205
10-20-2013, 01:48 PM
You can pick up doghouse hinges with removable hingepins, which makes pulling the motor cover out when you need to REALLY easy. Worth putting them in if you're pulling the floor anyway, IMO.

Which ones do you mean? have a link?

Table Rocker
10-20-2013, 02:00 PM
http://christinesmarine.com/image/47328355_scaled_320x240.jpghttp://christinesmarine.com/image/46892219_scaled_320x240.jpg (http://christinesmarine.com/interior-parts---accessories.html)

thatsmrmastercraft
10-20-2013, 02:09 PM
http://christinesmarine.com/image/47328355_scaled_320x240.jpghttp://christinesmarine.com/image/46892219_scaled_320x240.jpg (http://christinesmarine.com/interior-parts---accessories.html)

I have those in my boat and they are slick.

mikeg205
10-20-2013, 02:12 PM
http://christinesmarine.com/image/47328355_scaled_320x240.jpghttp://christinesmarine.com/image/46892219_scaled_320x240.jpg (http://christinesmarine.com/interior-parts---accessories.html)

I can see that hinge grabbin' my pinky toe... ouch... just me bein' clumsy....lol - don't take much for me to walk into sumfin... lol - just did this 8 weeks ago...doh!

thatsmrmastercraft
10-20-2013, 02:13 PM
Have yet to have anyone catch a toe on my boat. I've had her since 2008.

mikeg205
10-20-2013, 02:23 PM
Have yet to have anyone catch a toe on my boat. I've had her since 2008.

I may have to take that risk... now.. I hate removing half the hinge over winter... is there a link to those exact hinges? I only find the smaller ones.

thatsmrmastercraft
10-20-2013, 02:28 PM
I may have to take that risk... now.. I hate removing half the hinge over winter... is there a link to those exact hinges? I only find the smaller ones.

Mine came with my boat. I will have a look around.

thatsmrmastercraft
10-20-2013, 02:48 PM
http://www.attwoodmarine.com/store/product/stainless-steel-hatch-hinge

Table Rocker
10-20-2013, 03:16 PM
I may have to take that risk... now.. I hate removing half the hinge over winter... is there a link to those exact hinges? I only find the smaller ones.

http://christinesmarine.com/image/47328355_scaled_320x240.jpghttp://christinesmarine.com/image/46892219_scaled_320x240.jpg (http://christinesmarine.com/interior-parts---accessories.html)
Click the pic and scroll down. It is one of those sites where you can't link a specific item.

Table Rocker
10-20-2013, 03:29 PM
Here is one on eBay:
http://i.ebayimg.com/t/GEM-PRODUCTS-HINGE-BLUWATER-P-1128306-HINGE-MOTOR-BOX-/00/s/MTIwMFgxNjAw/z/DSUAAOxy9xhSD7lq/$T2eC16R,!)UE9s3wCMz2BSD7lpmOeg~~60_12.JPG (http://www.ebay.com/itm/GEM-PRODUCTS-HINGE-BLUWATER-P-1128306-HINGE-MOTOR-BOX-/231034782181?pt=Boat_Parts_Accessories_Gear&hash=item35cabf01e5&vxp=mtr)

mikeg205
10-20-2013, 03:43 PM
thanks rocker and that's - sorry about the thread jack OP

Jeffer
10-20-2013, 03:54 PM
Thanks for posting a link! I think West Marine sells them too. I stepped away to watch some football!
:)

mgs96ps
10-20-2013, 04:59 PM
thanks rocker and that's - sorry about the thread jack OP

You will never need to worry about a tread jack with me...I prefer letting treads lead where they lead...it much more interesting. However you guys are making my first winter project bust its budget!

thatsmrmastercraft
10-20-2013, 05:01 PM
You will never need to worry about a tread jack with me...I prefer letting treads lead where they lead...it much more interesting. However you guys are making my first winter project bust its budget!

Get used to it.:rolleyes::D:D

mikeg205
10-20-2013, 05:06 PM
You will never need to worry about a tread jack with me...I prefer letting treads lead where they lead...it much more interesting. However you guys are making my first winter project bust its budget!

We are very good at spending other peoples money. :)


Get used to it.:rolleyes::D:D

You'll see that our ability to spend other peoples money allows them to do more and get stranded less. In the end you'll get to do more for the same amount of money... At least that's the intent.. ;)

Didn't think I was buying a new raw water pump - till I read a thread this AM and check mine with a flash light just see the one o-ring I can see. We enable the MC-OCD really well.

Cloaked always will post a picture that can make you frantic and buy something not expected.... but always a good preventative maintenance enablement... just sayin'

thatsmrmastercraft
10-20-2013, 05:10 PM
My hinges use a stainless low profile torx head machine screw and a stainless locknut. Don't be hatin' on my motor cover, it came from a boat that was sucked out of a barn by a tornado. Crack repair are on the Spring To Do List.

The cord on the floor is for the quartz heater I just put in the boat since I haven't winterized it yet. Going down into the 20's tonight.

mikeg205
10-20-2013, 05:20 PM
My hinges use a stainless low profile torx head machine screw and a stainless locknut. Don't be hatin' on my motor cover, it came from a boat that was sucked out of a barn by a tornado. Crack repair are on the Spring To Do List.

The cord on the floor is for the quartz heater I just put in the boat since I haven't winterized it yet. Going down into the 20's tonight.

poop - I surely would walk in those hinges... I am always crackin' my feet into something.. not payin' attention.... ouch... 20's tonight - that stinks.. I don't think we are gonna get another nice day till spring.... along with the time to take advantage of it.

thatsmrmastercraft
10-20-2013, 05:29 PM
poop - I surely would walk in those hinges... I am always crackin' my feet into something.. not payin' attention.... ouch... 20's tonight - that stinks.. I don't think we are gonna get another nice day till spring.... along with the time to take advantage of it.

We have a few cool days ahead of us.

mikeg205
10-20-2013, 05:33 PM
We have a few cool days ahead of us.

ouch... Corey posted snow pic's in Rush City ---

thatsmrmastercraft
10-20-2013, 05:40 PM
ouch... Corey posted snow pic's in Rush City ---

That just means it's time to allow my MCOCD to flow over to my sled for a while.

mikeg205
10-20-2013, 06:12 PM
That just means it's time to allow my MCOCD to flow over to my sled for a while.

Oh what sled to you have? Traxxx is always looking for sledders - he heads up your way...

hmmm... finding out more and more TT'rs are sledders too.. :)

thatsmrmastercraft
10-20-2013, 06:39 PM
Oh what sled to you have? Traxxx is always looking for sledders - he heads up your way...

hmmm... finding out more and more TT'rs are sledders too.. :)

I've got an older Polaris. It's a 96 XCR 600 SP. Three cylinder with factory triple exhaust. Not quite the hole shot of the newer 700's, but not many factory sleds can keep up with me on a rail bed or across a lake. I haven't ridden in MN for quite a few years. I do all my riding in Northern WI.

Jeffer
10-20-2013, 06:50 PM
Maybe these? Although I don't know if 2 screws on each half is enough. These aren't a removable pin, but they slide apart...so no messed up toes.

http://www.westmarine.com/webapp/wcs/stores/servlet/ProductDisplay?catalogId=10001&storeId=11151&partNumber=7219330&langId=-1&searchKeyword=Take+apart+hinge#.UmRdxDK9KSM

mikeg205
10-20-2013, 06:59 PM
I've got an older Polaris. It's a 96 XCR 600 SP. Three cylinder with factory triple exhaust. Not quite the hole shot of the newer 700's, but not many factory sleds can keep up with me on a rail bed or across a lake. I haven't ridden in MN for quite a few years. I do all my riding in Northern WI.

Give traxxx a shout he rides in WI or UP mostly