Anyone redone a cabin sole?

emergpa1 · Nov 9, 2011

ruidh said:
This is my next big project and it scares me a little. I think I'm going to have to tackle this because I have a awful mildew problem on this boat. Most of the deck leaks have been fixed. I have one stubborn portlight that needs fixing. I have Casey's book, but it doesn't even touch what to do if the expanding wood has pulled the two layers of fiberglass apart.

Pictures help a lot.

Tom J · Nov 10, 2011

Yep, been there, done that. Replaced the sole of my 1971 23' O'Day pop-top back around 1995. The project coincided with dropping the keel and replacing the keel bolts. The front two keel bolts had pulled part-way through the hull, and the boat almost sank at the mooring. The rigging had always been hard to keep in adjustment because the mast step kept sinking into the soggy sole. So, took most of the summer that season and ripped out the sole, repaired the keel socket, and put in the new sole. I have pictures I can send, but I haven't done that before, so you might have to bear with me.

Tom J · Nov 11, 2011

O'Day 23 sole replacement

Hopefully these pics will make it to the site and be helpful to you. The threaded rods visible in a couple of the keel bolt holes are 3' rods I threaded into the keel to guide it and hold it steady while I lowered it and then re-inserted it. The front two keel bolt holes were ground out and then repaired with layers of fiberglass. The rest of the keel bolt holes were filled with an epoxy and high-density filler mix, and then all the holes were re-drilled. The holes were ground level with the top of the keel socket, and longer keel bolts were installed.
I used marine-grade plywood for the new sole. The wood was cut according to the outline of a template made from cardboard, and then sealed with several coats of epoxy. I used West System epoxy throughout the project, even for the fiberglass. Before the wood was laid down, I installed wooden stringers to the hull to support the edges of the wood, and to support under the mast step. These were sealed in epoxy and then epoxied in place. In addition, I molded supports for the sole around the c/b down-tube. These were also epoxy with high-density filler.
The entire sole was then covered with a single layer of fiberglass, 1/4" thick, with mat on one side and woven on the other side, using epoxy. Very strong and durable.
I used a single-part paint to finish the sole, but I would suggest a two-part paint that would adhere better to the epoxy.
I hope this helps with your project. I'll be glad to answer any questions.

Tom J · Nov 11, 2011

Sounds doable. Might be less work. I've just never had much luck re-using materials like that. In my case, the underside of the sole was shot as well, so it seemed like a good idea to just replace the whole sole. Plus, I had that issue with the keel bolts.

Capn Pete · Dec 9, 2011

ruidh said:
Don Casey talks about cutting out the fiberglass, replacing the wood (in pieces!) and epoxying the fiberglass that you removed onto the new plywood and then grinding and fiberglassing the seam.

The sole in EmmieLou is looking a little tired, past the point of just sanding and revarnishing. I was thinking of replacement, but I thought I'd look into using laminated flooring suitable for below-grade installation (from a big-box home supply store), since it's way-y-y cheaper than buying marine flooring from a chandlery. Reactions, suggestions, etc.?

Pete
s/v EmmieLou (O-322)
Little Silver, NJ

CPseudonym · Dec 16, 2011

Capn Pete said:
The sole in EmmieLou is looking a little tired, past the point of just sanding and revarnishing. I was thinking of replacement, but I thought I'd look into using laminated flooring suitable for below-grade installation (from a big-box home supply store), since it's way-y-y cheaper than buying marine flooring from a chandlery. Reactions, suggestions, etc.?

Pete
s/v EmmieLou (O-322)
Little Silver, NJ

If you try it please let us know how well it works. I am currently installing a similar product throughout my house. It sure installs easy.

Craig

RECESS · Dec 17, 2011

I got my issue of Good Old Boat today. On page 30 - 33 is a step by step of doing a cabin sole on a 31' using bamboo home flooring.

emergpa1 · Dec 19, 2011

Great, i love good old boat. i hope mine is in the mail when i get home.

CPseudonym · Dec 19, 2011

RECESS said:
I got my issue of Good Old Boat today. On page 30 - 33 is a step by step of doing a cabin sole on a 31' using bamboo home flooring.

I'm not familiar with the publication but will google it. Do they have recommendations other than the factory ones in the box if I strike out finding it?

Capn Pete · Dec 20, 2011

RECESS said:
I got my issue of Good Old Boat today. On page 30 - 33 is a step by step of doing a cabin sole on a 31' using bamboo home flooring.

Great! Thanks for the tip! I'll check it out before proceeding.

Pete
s/v EmmieLou (O-322)
Little Silver, NJ

RECESS · Dec 20, 2011

CPseudonym said:
I'm not familiar with the publication but will google it. Do they have recommendations other than the factory ones in the box if I strike out finding it?

If you have a Books-A-Million or Barnes and Nobles near they should have the January issue in the boating magazines. Good Old Boat is a DIY magazine for sailboat owners. It specializes in boats over 20 years old. The article was just how one owner did his cabin sole. It is the best sailing magazine I have had the pleasure to subscribing to. Many of the articles are from members of SBO.

CPseudonym · Dec 20, 2011

RECESS said:
If you have a Books-A-Million or Barnes and Nobles near they should have the January issue in the boating magazines. Good Old Boat is a DIY magazine for sailboat owners. It specializes in boats over 20 years old. The article was just how one owner did his cabin sole. It is the best sailing magazine I have had the pleasure to subscribing to. Many of the articles are from members of SBO.

I will drive to Barnes and Noble tomorrow. I am finding many great resources on this forum. Thanks RECESS.

~Craig

Capn Pete · Jan 9, 2012

Help!

RECESS said:
I got my issue of Good Old Boat today. On page 30 - 33 is a step by step of doing a cabin sole on a 31' using bamboo home flooring.

Dave,

I'm having the damnedest time finding a newsstand copy of GOB. Any chance you could scan the article and send it to me off-list? (I promise not to rat you out to the good folks at the magazine.)

Pete
s/v EmmieLou (O-322)
Little Silver, NJ

Capn Pete · Jan 25, 2012

Capn Pete said:
Dave,

I'm having the damnedest time finding a newsstand copy of GOB. Any chance you could scan the article and send it to me off-list? (I promise not to rat you out to the good folks at the magazine.)

Pete
s/v EmmieLou (O-322)
Little Silver, NJ

Belay that last request. I came up with a copy. The project looks like a winner.

Pete
s/v EmmieLou (O-322)
Little Silver, NJ

emergpa1 · Jan 25, 2012

Capn Pete said:
Belay that last request. I came up with a copy. The project looks like a winner.

Pete
s/v EmmieLou (O-322)
Little Silver, NJ

ayi capn pete. no worries ehh?

Capn Pete · Jan 28, 2012

emergpa1 said:
ayi capn pete. no worries ehh?

Nope. First step, like the article says, is to test some samples of the flooring material by dunking them in a bucket of water to see if they warp or delaminate. After that, it's just pattern-making, measuring (twice, if not thrice), cutting and installation. How tough can 40-50 square feet be? (Dangerous question, for sure.)

Pete
s/v EmmieLou (O-322)
Little Silver, NJ

emergpa1 · Jan 31, 2012

Capn Pete said:
Nope. First step, like the article says, is to test some samples of the flooring material by dunking them in a bucket of water to see if they warp or delaminate. After that, it's just pattern-making, measuring (twice, if not thrice), cutting and installation. How tough can 40-50 square feet be? (Dangerous question, for sure.)

Pete
s/v EmmieLou (O-322)
Little Silver, NJ

yes, it's all those curves and little angles that get u. get a good scribbing tool, and cut a bunch of strips of cheap plywood the size of your flooring strips. they are your error savers. did you notice how in the article he still had gaps along the edges? he filled that in with caulk, which of course is going to pull away with time and shrinkage, quickly too. , then you get moisture under the planks...... the project and outcome didn't seem to be appealing.

Anyone redone a cabin sole?

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