www.iFourWinns.com

Our 1996 Sundowner 205 DLX definitely has nine lives! We had a transom repair that turned into an engine rebuild and now that the boat is running like it did in 1996. One thing that always bugged me was the floor was sagging. After removing the screws, I pulled up the center floor cover and was met with the ugly blight of wood rot. Yikes.

https://www.dropbox.com/scl/fi/brjsou70ufoupzn1v0k84/FLOOR1.jpg?rlkey=65g4f253opf0e7vgzuj441plk&st=num1v5tt&dl=0

I set out to replace the floor support as this was absolutely necessary no matter what I wanted to do next. I measured each of the pieces. The entire framework is installed by screws, so after removing some 16 screws I was able to wrestle the boards out of the cockpit.

https://www.dropbox.com/scl/fi/s74gqo28ssjwby9glumke/FLOOR0.jpg?rlkey=8z9m5g34dtqnb4cn0mdhdhaby&st=002y3n90&dl=0

The wood was so badly splintered some of it crumbled in my hands. I can't say what type of wood was used under there, but it was very cheap and hardly seemed marine grade. It looked more like pressed plywood. Just awful. Here's the good news: the rest of the wood under there (along sides of gas tank and walls) was fine. It looked great - nothing to complain about. For my replacement framing I looked into marine grade wood here in Portland but it was ridiculously expensive because I would need custom cuts. The side rails were 1 x 3's, the crossbars were 1 x 2's. You just don't get anything like that off the shelf anywhere. I supposed I could have gone with thicker wood without any issue, but I wanted to keep the replacement sizes the same. With a little research I came upon 5/4x4 primed wood used mostly as trim for houses. They are water resistant and the real-world measurement was 1 x 3.5 inches. They also have a 1 x 2.5 inch length. The extra .5 inches would work under the floor (above the gas tank) with no issue, so I bought two 16' lengths - the only size they sell them. I used the measurements to recreate the rails and slots for the wood crossbars. A bandsaw was used to make the cuts.

https://www.dropbox.com/scl/fi/q0q3emx96h9nl7p4dda99/FLOOR9.jpg?rlkey=fqarh9yz3kvsp9hph55ym4gfz&st=oyuywgzo&dl=0

I laid the structure on the garage floor to make sure the cuts were flush.

https://www.dropbox.com/scl/fi/64bul4crx85q9a7bjaymg/FLOOR2.jpg?rlkey=r2nxit36o168vs5kmvmk784o3&st=vhs2txsa&dl=0

Next step, assemble the materials on the boat.

https://www.dropbox.com/scl/fi/zt8t3r2kw360egxav6lb1/FLOOR8.jpg?rlkey=y8jfvt1xdvh9gvtjr1ofmcdia&st=g5uwwtpz&dl=0

It was pretty easy to line up the top of the first siderail to where the old one used to be. I drilled a couple of new holes through the wood into the wall to support the first side. Note that I had to cut out a piece near the gas hose because the 3.5" length would press up against it and didn't want vibration ro cause any issues.

https://www.dropbox.com/scl/fi/i66xgjdljpi2g539qz3oe/FLOOR3.jpg?rlkey=mwhn3go17rqk9i77979soiqv5&st=i0hpoh37&dl=0

Note, too, I treated the open cuts with Copper Green Wood Preservative, just as an added precaution. In fact, I sprayed the Copper Green on the gas tank wood supports as well, knowing full well it probably wouldn't make a difference there - but every little bit helps. The sides and the wood wall at the engine were strong and, after almost 30-years of boating, sturdy. I didn't spray there. Evidently not a lot of water gets into that area of the boat. If it does, it comes from water on the carpet above. Years of kids water skiing, etc. probably did that floor in. Everything lined up perfectly as I screwed in the second support rail and dropped in the crossbars.

https://www.dropbox.com/scl/fi/1c8o5r49dduoj0fbqqeho/FLOOR4.jpg?rlkey=qdsrqc847wtprnbdu659pfbb0&st=ck2mn59i&dl=0

I did have to shim one of the crossbars to insure it was flush. It was treated with Copper Green and glued into the slot. But it all came out flush. Each of the crossbars needed to be secured with a screw (that's the way it was assembled at factory).

https://www.dropbox.com/scl/fi/cbd2btsuxftcracl8tjbq/FLOOR5.jpg?rlkey=li5wc75k0853vatu2nyl677vz&st=rx2gsngc&dl=0

Once assembled it looked like it should. I thought about adding another crossbar, but that might have been a bit of over-engineering. At this point it was time to put the cover back on and screw down (15 times) the lid. Presto.

https://www.dropbox.com/scl/fi/y8wvfjpiyc8txp5y6q2xs/FLOOR6.jpg?rlkey=hknk81yf92kizx9jocje6y24c&st=h8kcf61w&dl=0

It feels solid, like when we first bought it. There's no give on the floor anymore. I would have loved to replace the plywood cover, but finding matching carpet is about impossible. Besides, that plywood was in good shape. (I may treat the underside with Copper Green someday.) If you have any ideas, let me know, Someday I'll replace ALL OF THAT almost-30-year-old carpet...but it works for now.

You are all more resourceful than I - so add your tips and what worked for you. As for me, i am glad this project is over.

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Four Winns 1996 Sundowner 205
5.0fi/SX engine (Volvo Penta)

I did that job & much more about 20 years ago on my 1988 H200. The rest of the floor from the helm to the engine was rotted on both sides as were some of the stringers. Ripped it all out and had a glass shop do the parts I couldn’t do well. For the part you showed here, the gas tank supports, I used mahogany which is very rot resistant. If you used pine I’d have coated it all in resin or at least painted it with a good outdoor paint. IMHO, carpet is bad bad bad in a boat with wood cored decks. I got rid of ALL of it and had the deck gel coated in non skid gel coat. The carpet holds moisture against the wood deck and the rot will start where there are holes drilled for seats etc and on the edges of panels. So 18 years later mine is still solid. Open boat with wood decks say NO to carpet! The glass work in this boat was ok on the hull but the wood was totally unprotected. I made it the best I could & it’s lasted a long time. If I had your boat that carpet would be gone and the whole deck refinished in ‘glass & gel coat or even an industrial deck paint.

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88 Four Winns 200 Horizon
4.3 OMC Cobra-4bbl
2002 Walker Bay 10/2012 Suzuki 2.5
2008 Walker Bay 8

1998 Jeep Grand Cherokee 4.0/Selectrac
2007 Jeep Grand Cherokee 5.7 Hemi/Quadradrive II

It was a BIG job, but I am so glad I ditched that lousy carpet and all the problems it causes. Maybe if you live in the arid southwest it's ok but in a damp climate it ruins boats!
It really depends on how long you'll think you'll keep it. Long time, ditch the carpet!

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88 Four Winns 200 Horizon
4.3 OMC Cobra-4bbl
2002 Walker Bay 10/2012 Suzuki 2.5
2008 Walker Bay 8

1998 Jeep Grand Cherokee 4.0/Selectrac
2007 Jeep Grand Cherokee 5.7 Hemi/Quadradrive II

Lou, we live in the rainy Pacific Northwest. I know, I know.

What saved the boat all these years is that it is stored indoors in winter. And during summer we see very little rain. It's led a charmed life. Except once a year it is dipped into salt water for a week or more of Salish Sea boating (the best). Check out our visit to Roche Harbor, WA.
https://www.dropbox.com/scl/fi/tcr2jzp9q7eg94sudwvxh/01717_bA1OMKPrR2I_0ww0oo_1200x900.jpg?rlkey=zw4v942v82ywdenepwx8sa7xu&st=jfas7swo&dl=0

...and through the Pender Canal (between North and South Pender Islands, Canada)(riding rapids during tides)
https://www.dropbox.com/scl/fi/eacojueq2h4hpmnq8yx0b/07Orcas196.jpg?rlkey=kt7mrt1igxs86tf4vxb0gt2ty&st=txkq8ftp&dl=0

...on the water heading towards Saturna Island, CA.
https://www.dropbox.com/scl/fi/ev33v8ye86l964qtss0vt/IMG_9408.JPEG?rlkey=bime4t2b8swojyupc6i14q2ez&st=deypndt2&dl=0

Boating allows is to see things few others get to experience. Having said that...I would love to try and update the floor, but it is time to let the boat go to someone who wants to keep the FW205 Sundowner legacy going. With the new engine she'll last longer than I will be alive.


...but a new floor sounds enticing.

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Four Winns 1996 Sundowner 205
5.0fi/SX engine (Volvo Penta)

OK if your boat is stored inside, then it's not out in the moisture all year like most are here and so the decking is probably in much better shape than is typical. If you were going to keep the boat indefinitely, I still think getting rid of the carpet, and having the deck (if still solid) refinished in 'glass and non skid gelcoat. That would add years of life to it, as it has to mine. If you would sell and not get back into boating that's one thing but if you might, well check used boat prices. People are asking $20K for junk, new boats are out of sight expensive like new vehicles.

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88 Four Winns 200 Horizon
4.3 OMC Cobra-4bbl
2002 Walker Bay 10/2012 Suzuki 2.5
2008 Walker Bay 8

1998 Jeep Grand Cherokee 4.0/Selectrac
2007 Jeep Grand Cherokee 5.7 Hemi/Quadradrive II

....trouble is, not many are buying.

I started the summer advertising my boat for sale. I wondered why it was so slow. I checked into it and there were 1100 boats for sale on the site.

I think people must be in a downsizing phase again, liberating assets.

Given the economic uncertainty, boats are a luxury that might be low on people's priority list. Even a smaller one like mine.

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Four Winns 1996 Sundowner 205
5.0fi/SX engine (Volvo Penta)