Originally Posted by F470
Bear with me on all the questions just trying to make sure I don't wreck the boat or the floor by not having it fit correctly.
So when all but one panel are fitted snugly there's about 3" of overlap as you can see here. I also included an image of what it looks like before you push it in place. Does this look normal? Should the boat be completely without air when installing or it ok to have it halfway pumped up? I figured it may stretch more without any air.
Sorry coming in late to this thread but I have some insight. I've had dozens of F470s over the years and I've run into this before. I came to the conclusion the hard deck floors are all the same length and the variations were in the boats themselves. I don't know if it was design changes, manufacturing tolerances or whatever but some boats interior dimensions were 1-2" shorter than others. When I first ran into this I had the exact same scenario: floor seemed to be 2-3" too long for the boat. Keep in mind the floors are supposed to fit "tight" however this was excessively so.
Not knowing any better (this was the first time we encountered this), and on the advise of another buddy who had extensive experience with these attack ducks, we just forced the floor in. At first it seemed fine. About a month later the boat developed a leak. The source of the leak wasn't apparent until the next time I dropped it in the water...it was bubbling out the edges of the thrustboard in the bow on one side. Look closely where the thrustboard meets the floor. There are about 4 seams that overlap there. The stress pulled it apart. Talk about a nightmare repair...had to make a 9" access cut in the tube and patch from the inside then use inside and outside patches on the access cut. The repair was bombproof (had a climate controlled shop at the time) but was a royal PITA. Long story short: if the floor is more than 1" longer than the boat DO NOT force it.
What we ended up doing was disassembling the rearmost floor unit (knock off the side rails, they come right off) then we slid out one of the "short" aluminum subsections and reassembled it. I want to say it subtracted about 1.5-2" from the floor length. It fit perfect after that. Be careful though do not make the floor too short...ran into that too and the result will be a leak at the transom where the tube met at the bottom from chafing the the too-short floor...ask me how I know :-/