How to Fix Ski Boat Flooring

When the deck of a ski boat sustains damage, it is almost certain that it will break or crack under or around the ski pole, to which the skier's tow rope is attached. The energy to move the skier through the water passes from the boat to the tow rope attached to the top of the pole, through its tripod-like base. The tow rope then transmits the kinetic energy of the boat's movement to the skier -- until the flooring breaks. The repair, if done properly, supplies a "fix" that prevents it from reoccurring.

Things You'll Need

  • Adjustable wrench
  • Screwdriver
  • Jigsaw
  • Measuring tape
  • 3/4-inch marine plywood
  • Screws
  • Screwdriver
  • 1 1/2-ounce fiberglass mat
  • 6-ounce fiberglass cloth
  • Marine epoxy
  • Clean container
  • Putty knife
  • 420-grit sanding papers
  • Palm sander
  • Clean cloth
  • Acetone
  • Wax
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Instructions

    • 1

      Remove the ski pole from the damaged section of deck, using an adjustable wrench or screwdriver. Look beneath the damaged area, if possible, to locate wires, cables, hoses or piping that run through the area.

    • 2

      Cut the damaged area out of the deck with a jigsaw. Take care not to cut any lines, wires or cables below the deck. Remove the damaged deck. Measure the length and width of the section you remove, using a measuring tape. Add 5 inches to each of these dimensions. Transfer these new dimensions to a sheet of 3/4-inch marine plywood. Cut the section from the sheet of marine plywood.

    • 3

      Position the plywood over the hole in the deck. Drive 1/2 screws through the plywood and the deck, using a screwdriver Cut two sheets of 1 1/2-ounce fiberglass mat and two sheets of 6-ounce fiberglass cloth using heavy shears, so that each is 5 inches larger in all dimensions than the top surface of the plywood.

    • 4

      Mix marine epoxy in a clean container and apply it to all the exposed surfaces of the plywood with the blade of a putty knife. Position the fiberglass mat on the epoxy and apply a second layer of epoxy. Press fiberglass cloth onto the second layer of epoxy. Repeat.

    • 5

      Allow the new fiberglass to cure fully. Sand the new fiberglass, using 420-grit sanding papers and a palm sander. Clear the sanding dust off the fiberglass with a clean cloth saturated in acetone. Paint the fiberglass, if desired, and when the paint dries, wax it. Re-attach the ski pole, using the fastenings that originally held it in place.