Chapperal Restoration
This 1975 Chapperal 18 Bow Rider was brought to us as shown in the first few photos with a rotten deck. Trees were growing in it.
The old floor was cut out with a sawsall, chisel and angle grinder and then the surface was scrubbed with Dawn dishwashing liquid to remove oil residue. Finally the surface was wiped with acetone to catch any remaining contamination and evaporate any remaining water.
A single coat of un-thickened resin was rolled on to provide a good bonding surface. Using a straight edge and tape measure, the hull was marked off at one foot intervals and the vertical height of the new floor was calculated.
Two pieces of 3/4" high-quality outdoor plywood were marked and cut for the stringers that would support the floor. Each component was test fitted then given two coats of polyester resin to seal out moisture and provide a good bonding surface. The upper box beams were screwed in place with outdoor decking screws. The center stringer is made of two shaped 3/4" boards screwed together with a layer of resin saturated chop strand between each board. All seams were staggered for strength.
A half-round fillet of resin/cabosil mix was spread into the corners where the stringers join the hull. This was done so that the three layers of fiberglass chop strand that came next would have a smooth curving surface to follow in transition from stringer to hull. Fiberglass cloth hates sharp angles.
With the support structure tabbed in place, more 3/4" plywood was cut for the deck itself, test fit, and then coated twice on both sides with resin. A paste of cabosil/resin mix was knifed onto the top of each stringer and into the corners to insure a watertight bond, then the boards were screwed down on 8" centers into the putty.
With the new deck down, the next step was to bond the floor to the sides of the hull with three layers of chop strand. A final layer of chop strand was air-rollered in a single continuous sheet over the entire floor and eight inches up the hull sides to provide a smooth, strong and abrasion resistant surface.
Large doubler pads of 3/4" plywood were screwed, bonded down, and glass encapsulated to the floor where the seat pedestals will be lag screwed down. These pads will distribute the load of occupied seats posts levering the floor as the boat drives into chop.
With the floor structurally complete, two coats of gelcoat was rolled on and spatter coated, adding a non-skid, protective and attractive outer skin.
Lastly, the deck and hull were primed and painted. The vintage Chapperal is now ready for new seats, a motor, splash and thirty more years of fun on the water!
