Originally Posted by F470
I took the floor apart and here are some more photos. Even though it appears from the top that the panels aren't fully flush it turns out the are indeed flush. See photo. One of the panels end pieces is loose and wiggles around and has a crack in it. This concerns me a bit. Should I try to weld this so it doesn't move? There are some holes with what appears to be inserts. Are those steel inserts or just remnant corrosion from some other part? Also there are some corrosion holes. Should I fix those with alumiweld? Not sure there is much else I can do to fit the panels together more snugly. I suppose I could trim the back end panel slightly in order to reduce pressure lengthwise but I am hesitant to do an irreversible modification. I just don't want the thrust board to delaminate from the pressure (it already is in one corner).
On the cracks those are common the military (esp USMC) puts these boats through hell. There was actually a preventative field fix for this called the "CMK" (Craft Modification Kit) which included ONE PIECE SOLID stringers (a single 8-9' stringer replacing the multiple hollow extrusions on each side). John at ACT in Orlando used to sell these along with the other CMK components (aluminum thrustboard reinforcement plates and stainless steel transom reinforcement/cap). If you look close at my "current rig" pics you can see these installed into my boat.
Anyway If you don't plan on throwing 10 heavily loaded troops in your boat and hitting heavy seas then you probably don't need the upgrade and you'll be fine. I personally would TIG weld up the crack just so it doesn't get worse and to clean up the sharp edge that could potentially puncture the boat.
All those holes are from the other random stuff the military or previous owner installed. The most common are a series of holes they laced webbing through to make handholds/footholds. I leave them in place on my boats they are quite handy for securing persons/gear and add more "authenticity" to the boat :-)