It's all new ply. 9mm Meranti from Plytech https://www.plytech.co.nz/meranti-bs1088
The floor boards required 2 sheets of 2440 x 1220 for the Oliver Sudden. I purchased 3 sheets, and using the 3rd sheet for other projects.
Looked at a few options to replace the original Holy and Teak floors. They were delaminating after 35 years of hard service. They were beyond repair.
9mm is probably marginal for floor boards, but adjusting the thickness required too many modifications. So sticking with the 9mm and some carefully placed extra thickness / reinforcing.
Looked at Holy and Teak, $1,000 a sheet. Too pricing and the new veneer finish isn't gonna match the ages and sun-faded Teak trim on-board.
Also looked at this recycable synthetic honeycomb from Plytech as an option too. Would have been much quicker, albeit a little industrial looking.
So tried a couple of other Marine ply samples and Meranti wasn't too bad. A little bit darker / reddish than teak interior. Thought I'd try to paint some lines as a nod to the old school Holy and Teak look.
Here's the Process....
Take the original floorboards and trace with a router with router bit and bearing / I used 10mm. Simple, just take your time. You want to line up the floor boards and grain.
Marked out the exact location of the Holy Lines with a pencil. They all line up, so this needs to be accurate.
4 seal coats of Norski Epoxy Timber Sealer
Sanded and cleaned.
Mask up the "Holy Lines" with masking tape. I used a few and found ScotchBlue Sharp Lines to be the best.
Painted the Holy Lines with 2 Pack White Under-coat.
Try to get the White Lines done in a couple of days, otherwise the masking tape will be a PITA with residue.
Varnish 6 coats
For the varnish I used a Satin Single Pack I've used in the interior already. I seems to be tough enough.
I'm not a fan of buying from Bunnings and supporting the West Island, but this stuff seems good. Bondall 1L Monocel Clear Satin Gold Marine Grade Timber Varnish.
I've been damn lucky with the fine weather for varnishing. Hopefully it looks all good when we can finally get back onboard.