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2003 VLX floor repair?


BillyChinookVLX

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My 03 VLX has developed a couple soft spots in the floor panel that covers the fuel tank. Seems like somebody could have taken a hard step heel first and put a dent/weak spot the size and shape of a heel in the floor. (Not pointing fingers…. But my buddy who is frequently on the boat with us weighs probably 280 and is anything but graceful) I pulled the panel out and found out that it’s 1” aluminum honeycomb panel. Being 20 years old some of the interior honeycomb is rotted out.

has anybody done a successful repair on these floors? I’m thinking along the lines of drilling in from the bottom under my soft spots and injecting either a foam or epoxy/resin material. I’m really hoping to avoid replacing the panel, I can’t imagine that material is cheap and matching carpet will be a challenge for sure. 
 

Thanks for your ideas and input!

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That's exactly what I did. On the edges I gently "peeled" the hexagon aluminum where it was damaged to expose in tact and undamaged aluminum, and in the dented areas I drilled several holes and then filled it all with epoxy mixed with milled fiberglass for strength. Lastly, I covered the top of the panel (which seemed to be the weak point) with a single layer of resin with woven roving. It ended up super strong and probably saved me a bit compared to the alternative...but it was a bit of a pain.

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14 minutes ago, formulaben said:

That's exactly what I did. On the edges I gently "peeled" the hexagon aluminum where it was damaged to expose in tact and undamaged aluminum, and in the dented areas I drilled several holes and then filled it all with epoxy mixed with milled fiberglass for strength. Lastly, I covered the top of the panel (which seemed to be the weak point) with a single layer of resin with woven roving. It ended up super strong and probably saved me a bit compared to the alternative...but it was a bit of a pain.

Did you fill your soft spots only or try to fill the whole sheet?

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