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Old 10-16-2013, 11:54 PM
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mgs96ps mgs96ps is offline
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96 honeycomb floor...she gone

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.

Last edited by mgs96ps; 01-08-2014 at 09:28 AM.
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Old 10-17-2013, 12:16 AM
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JMLVMI JMLVMI is offline
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What's the weight difference?
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Old 10-17-2013, 12:24 AM
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mgs96ps mgs96ps is offline
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Originally Posted by JMLVMI View Post
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.
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Old 10-17-2013, 07:12 AM
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Quote:
Originally Posted by mgs96ps View Post
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.
too funny - but awesome..
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...A bad day water skiing still beats a good day at work...1995 Pro Star 205....
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Old 10-17-2013, 07:24 AM
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Bouyhead Bouyhead is offline
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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.
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Old 10-17-2013, 09:26 AM
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mgs96ps mgs96ps is offline
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Originally Posted by Bouyhead View Post
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?
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Old 10-17-2013, 11:10 AM
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markmcfarland markmcfarland is offline
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Probably a stupid question, but why would you need to replace the aluminum floor?
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Old 10-17-2013, 11:20 AM
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drschemel drschemel is offline
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Quote:
Originally Posted by mgs96ps View Post
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.
So, you add like 1200# balast to get a better wake but worried about 50# difference in flooring material?
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Old 10-17-2013, 11:32 AM
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Originally Posted by markmcfarland View Post
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.

Last edited by mgs96ps; 10-17-2013 at 11:48 AM.
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  #10  
Old 10-17-2013, 11:40 AM
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mgs96ps mgs96ps is offline
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Originally Posted by drschemel View Post
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.
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