Removing Aluminum Boat Floors: A Step-By-Step Guide

Removing the floor of an aluminium boat is a complex process that requires a range of tools and materials. The process involves detaching the boat seats and storage compartments, which are usually attached to the hull using solid aluminium rivets. These rivets need to be carefully drilled out to avoid damaging the surrounding material. Once the rivets are removed, the seats and compartments can be lifted out, providing access to the floor. The floor itself is typically held in place by aluminium pop rivets or screws, which need to be removed while being cautious not to damage the floor covering. It is recommended to have an extra pair of hands when lifting out the old floor as it can be heavy and awkward. After the old floor is removed, the floor covering can be cleaned or replaced, depending on its condition.

Removing the seats and storage compartments

First, gather the necessary tools. You will need safety gear, including safety glasses, hearing protection, and leather gloves. Additionally, you will need tools such as a drill, a drill bit set, a tapered punch set, and a screwdriver.

Next, locate the fasteners that secure the seats and storage compartments in place. These fasteners can be solid aluminium rivets or screws. If rivets are used, you will need to drill them out. Start by selecting a drill bit that is slightly smaller than the rivet to avoid damaging the surrounding material. Drill out the centre of each rivet, and then use a small tapered punch to break off the head of the rivet. This will leave the holes in the seat and boat hull undamaged.

Once all the rivets have been drilled out, remove any remaining screws along the base of the seats and storage compartments. Be sure to mark and tape together any foam pieces inside the bench seats for easy reassembly. If there is a live well, disconnect any hose clamps and hoses before removing it.

After all the fasteners have been removed, carefully lift out the seats and storage compartments. Get an extra pair of hands to help with this step, as these components can be heavy and awkward to handle. Pay attention to any wires or hoses that may be attached to these compartments, and carefully detach them.

Now that the seats and storage compartments have been removed, you should have full access to the floor. The next step is to remove the old floor, being cautious of any loose staples or sharp edges. It is recommended to wear leather gloves during this process to protect your hands.

Once the old floor is removed, you can decide whether to reuse or replace the floor covering. If reusing, clean it thoroughly and remove any remaining staples. If replacing, use the old floor covering as a template to cut the new one to size.

Finally, before installing the new floor, take the opportunity to inspect the bottom of the boat for any damage, such as loose rivets or signs of impact. This is also a good time to make any necessary repairs to the boat seat mounts or install upgrades like a bilge pump.

Drilling out the rivets

Understand the Rivets:

Before starting the drilling process, it is important to identify the type of rivets used in your boat. There are two common types: blind rivets (installed with a puller) and solid "driven" rivets. Blind rivets have a "core" and a locking ring that must be removed before drilling. Solid rivets, on the other hand, can be drilled out directly.

Centre Punch the Rivets:

Use a centre punch to mark the centre of each rivet head. This step helps prevent the drill bit from wandering and ensures a straight, accurate hole. Place the centre punch in the centre of the rivet head and apply firm pressure to create a small indentation.

Choose the Right Drill Bit:

Selecting the appropriate drill bit size is crucial. Start with a drill bit that is slightly smaller than the rivet diameter, preferably one size smaller. This will help ensure that you do not remove more material than necessary and create a larger hole. For example, if you are drilling out 3/16" rivets, use an 11/64" drill bit.

Drill Slowly and Carefully:

Set your drill to a slow speed and apply gentle pressure when drilling. Drilling at high speeds can cause the drill bit to temper the rivet, making it stronger and more difficult to drill. Take your time and focus on maintaining a straight, upright drilling position.

Drill the Head First:

Begin drilling at the head of the rivet, which is the side you can see and is usually dome-shaped. Drill slowly and carefully until you break through the head. You may need to adjust your drill speed and pressure as you go to prevent the rivet from spinning inside the hole.

Remove the Head and Punch the Rest:

Once the head is drilled off, use a punch or a small drift to knock out the remaining portion of the rivet. Alternatively, you can use a grinder to remove the head first and then punch out the rest of the rivet. Make sure to work lightly and carefully to avoid damaging the surrounding material.

Clean Up:

After removing all the rivets, clean the area to prepare for the next steps in the floor removal process. This includes removing any remaining rivet pins left after drilling and ensuring the area is free of debris.

Remember to wear appropriate safety gear, such as safety glasses and hearing protection, when drilling and grinding. By following these steps, you can effectively drill out the rivets and continue with the removal of your aluminium boat floor.

Lifting out the old floor

Before you begin, ensure you have the necessary safety gear, including safety glasses, hearing protection, and leather gloves. These will protect you from any sharp edges or debris that may be present during the removal process.

Start by removing the seats and any other storage compartments or equipment that are attached to the boat floor. This will give you full access to the floor and make the process easier. Be sure to mark the pieces and duct tape them together for easy handling and reassembly later.

The next step is to remove the fasteners that hold the floor in place. This could be aluminum pop rivets or screws. Carefully remove them, being mindful not to damage the floor covering. If the floor covering is in good condition, you may be able to reuse it, which can help reduce costs.

Once all the fasteners are removed, it is recommended to have an extra pair of hands to help lift out the old floor. Aluminum boat floors can be heavy and awkward to lift for a single person. Be cautious of any loose, rusty staples or sharp edges that could cause injury.

If you plan to reuse the floor covering, now is the time to clean it thoroughly. Remove any old staples or pieces of rotted plywood that may be stuck to the covering. You can use a pressure washer and/or a scrub brush to clean it effectively.

Finally, if you intend to use the old floor covering as a template for cutting the new floor, lay it out and flatten any creases or folds. You can use 2x4 boards and weights to help flatten them. This will make the process of cutting and installing the new floor more accurate and efficient.

By following these steps, you will be able to safely and effectively lift out the old floor of your aluminum boat, setting the stage for the next steps in the replacement process.

Removing the floor covering

If you plan to reuse the floor covering, now is a good time to clean it up. Remove all the old staples that may have broken off during the removal. Also, be sure to remove any pieces of the rotted plywood that may have pulled off and are still stuck to the flooring by the glue. Reusing the floor covering can easily save you $75 to $150, depending on the size of the boat. Also, having the creases and folds in the old floor covering makes the reinstallation much easier. And the original rivet holes that attached the floor to the boat can be a good reference for drilling and riveting the new floor back in place.

If you do not intend on reusing the floor covering, I suggest laying it out and flattening all the creases and folds. Laying some 2x4 boards on them with a little weight will help flatten them. The old floor covering will make a good template for cutting your new floor covering to size.

To remove the floor covering, set it up on a couple of sawhorses with the bottom side up. Remove the staples around the perimeter of the old floor. Normally, floor coverings are glued to the plywood, so you will need to slowly work it loose. Using a wide putty knife works well for this, as you lift and pull it away from the old plywood.

The difficulty of how it comes up depends on the type and amount of glue used. My vinyl floor covering actually came up quite easily. I only had to use the putty knife a few times.

If the carpet or vinyl floor covering is not damaged, reusing it is a great way to reduce the cost of the project. Before removing the floor covering, now is a great time to use a pressure washer and/or scrub brush to clean it.

Preparing the bottom of the boat for installation

While you wait for the paint to dry, it is a good time to prepare the bottom of the boat for the new floor installation. Start by thoroughly cleaning the inside of the boat. A pressure washer works great for this, effectively removing years of dirt and debris.

Next, remove the old rivet pins left after drilling out the rivet heads to detach the old floor. A few may fall out, but most will remain in the floor supports. You may need to use a combination of pliers or a hammer and a tapered punch to remove them all. This will ensure that the new floor sits evenly on all the existing floor supports.

Another useful tip is to mark the location of the hull cross members on the side of the boat. Make sure they are high enough to be visible once the new floor is in place. This, along with your diagram, will be helpful when installing the pop rivets to secure the new floor. Also, this is your last chance to take measurements for any floor supports and rivet hole locations.

With the boat floor removed, now is the ideal time to thoroughly inspect the bottom of the boat. Look for loose rivets, signs of damage from hitting objects in the water, and leaking. The easiest way to do this is to partially fill the boat with water. Do not completely fill a boat sitting on a trailer with water, as this could cause damage. Put just enough water to cover the rivets in the bottom of the boat.

Remember, the seats that were removed for the project add structural support to the boat's hull and are designed to keep water out, not in. That much internal water force and reduced structural strength could allow the boat to deform or bend. With water in the bottom of the boat, crawl underneath and look for any signs of water leaking. If you find any issues, circle the leaking rivet(s) or damaged spot(s) with a permanent marker, then drain the water and make repairs as needed. Now is the time to make the repairs while the floor is removed.

A leaking rivet can be easily repaired with the tools available for this project. We have already gone over how to remove (drill out) rivets, and the installation of solid rivets will be covered further down.

Frequently asked questions