Part 2: Installing the CCA Plywood
Step 2 of building our pontoon boats is the installation of the CCA plywood. This step is crucial as it ensures the durability and longevity of the flooring, which forms the foundation of the boat's structure. Here's how we do it:
Apply Butyl Tape:
The first thing we do is apply a strip of butyl tape across each crossmember of the boat frame. This tape is about 8 feet long and is crucial for preventing water from seeping between the deck boards. Without this tape, moisture could accumulate under the deck, potentially causing the vinyl flooring to become damaged over time. The butyl tape acts as a waterproof barrier that helps prevent unwanted water infiltration. We make sure to apply it evenly and securely to each crossmember to guarantee its effectiveness.
Choosing the Right Marine-Grade CCA Plywood:
The plywood we use is not your typical treated plywood. We specifically use Marine-grade CCA plywood, which is designed for marine environments and will resist water and moisture better than regular plywood. Marine-grade CCA plywood is chemically treated to provide better resistance to rot, fungi, and mildew, making it the ideal choice for building pontoon boat flooring. This special type of plywood is essential for ensuring the longevity and safety of the boat, especially given the constant exposure to water and the elements.
Laying Out the Plywood:
Once the tape is in place, we begin laying out the plywood. We ensure that the plywood boards are spaced 4 feet apart, with each board aligned to fasten securely on its assigned crossmember. This spacing is key for distributing the weight evenly across the boat's frame, helping to ensure that the boat remains stable and performs optimally in the water. This also ensures that we have enough support for the deck, preventing any sagging or warping that could occur if the spacing was too wide.
These crossmembers feature an ID diameter of 1 7/8" to accommodate fasteners. Fastening the Plywood:
After laying out the plywood, we secure it in place using marine-grade Xylan self-drill screws. These screws are specifically designed to work in marine environments, providing the strength and durability needed to hold the plywood securely. We place these screws every 16 inches along each crossmember. It's essential to drive the screws in no more than 1/8 inch deep to prevent any damage to the surface of the plywood. This careful attention to screw depth is important because it prevents the screws from leaving indents or divots in the wood, which would later be visible under the vinyl flooring and could affect its appearance and performance.
Sanding and Finishing the Floor:
Once the plywood is securely fastened, we inspect the entire surface to ensure that there are no high spots or imperfections. If we find any, we use an orbital or belt sander to smooth them out, ensuring an even and level surface for the next steps. This is an important process, as any unevenness can cause the vinyl flooring to wrinkle or fit improperly, leading to issues with the finish and potential premature wear.
Trimming the Edges:
The final step in the plywood installation process involves trimming any outside corners or profiles that will be covered by the trim banding once the vinyl flooring is installed. This ensures that the edges are neat and ready for the next phase. By rounding off the corners and profiles, we give the boat a more polished, finished look that is both functional and aesthetically pleasing.
With the plywood securely installed, we now have a solid, water-resistant foundation ready for the next step: laying the vinyl flooring. Stay tuned!
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