Inflatable Boat Airfloor Replacement with Plywood - SailNet Community

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Old 07-14-2014
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Inflatable Boat Airfloor Replacement with Plywood

I am pondering the idea of replacing the air floor, which has since had a catastrophic failure, with plywood and wondering if anyone has successfully attempted this. Aside from the airfloor, the rest of the 9 foot Maxxon inflatable boat is in reasonably good shape and a replacement tender is currently unaffordable. The boat usually sits either in the water or on the deck of our sailboat year round so I am not concerned with portability, i.e. folding it up for storage.
I am thinking of using the existing airfloor as a template to cut out a single piece of plywood and cover the edges with a rubber hose or Styrofoam swim noodle to prevent chafing. I am not sure of what type or thickness of plywood I should use, or if this idea would even work. Any suggestions or experience with this type of project is greatly appreciated.
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Old 07-14-2014
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Re: Inflatable Boat Airfloor Replacement with Plywood

me too I need to make a plywood floor and looking for ideas on padding

hope you dont mind op
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Old 07-14-2014
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Re: Inflatable Boat Airfloor Replacement with Plywood

I have seen people that have good luck with pipe insulation also several use large rubber sheethed garden hose wrapped to protect from chaffing
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Old 07-14-2014
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Re: Inflatable Boat Airfloor Replacement with Plywood

I've done this. Be sure to SEAL the edges of the (exterior grade) plywood with epoxy. Best is to 'route out' a small amount of the inner plys along the edges and fill/fare with thickened epoxy. I used duct tape for chafe protection with no adverse effect to the hypalon.
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Old 07-14-2014
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Re: Inflatable Boat Airfloor Replacement with Plywood

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Originally Posted by RichH View Post
I've done this. Be sure to SEAL the edges of the (exterior grade) plywood with epoxy. Best is to 'route out' a small amount of the inner plys along the edges and fill/fare with thickened epoxy. I used duct tape for chafe protection with no adverse effect to the hypalon.
Thx RichH, do you recall what thickness of plywood was used, and did you cut just one piece for the entire floor, or connect several smaller pieces together?
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Old 07-15-2014
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Re: Inflatable Boat Airfloor Replacement with Plywood

If you don't need it right now, keep your eyes on the classifieds, I see wood floors come up every month or two.
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Old 07-15-2014
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Re: Inflatable Boat Airfloor Replacement with Plywood

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Originally Posted by twomikes View Post
Thx RichH, do you recall what thickness of plywood was used, and did you cut just one piece for the entire floor, or connect several smaller pieces together?
Why don't you just pop into a shop selling inflatables with plywood floors and have a look.
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Old 07-15-2014
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Re: Inflatable Boat Airfloor Replacement with Plywood

My Achilles is a wood floor type. I would guess plywood is 1/2 inch. It's in four pieces which makes handling and storage easier. In addition to channels to make the pieces move together, there are stiffening channels that snap onto the sides. I have used the floor without the side stiffening channels at times as they are a pain to put in and it works just fine without them. Just a bit less stiff.

Edit: Measured the plywood and it's closer to 3/8". I suspect it's really 1 cm as the boat was made in Japan.

Last edited by JimsCAL; 07-15-2014 at 09:11 PM.
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Re: Inflatable Boat Airfloor Replacement with Plywood

If you Google around, there are many threads, not just here but elsewhere, covering this subject
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Old 07-15-2014
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Re: Inflatable Boat Airfloor Replacement with Plywood

I have the plywood floor from a dead dink on the top deck and am going to cut it to size for our air floor KABOAT. Its only around 3/4 of the length of our current dink but no one sits up front there anyway.
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