How to Fiberglass a Small Boat Floor

Measure the width and breadth of the boat's existing flooring using a measuring tape. Transfer these measurements to a sheet of 1/2-inch marine plywood. Cut the measured portion from the plywood with a jigsaw.

Paint all surfaces of the plywood with an acrylic latex paint and a disposable paintbrush. Allow the paint to dry at least 24 hours, to ensure that it's thoroughly dry. Roughen the surface that will face up, using a palm sander and 40-grit sandpaper, to form a surface to which the epoxy can adhere.

Mix the hardener and resin from a marine epoxy kit together in a clean container, as directed on the kit's packaging. Don Casey, boating expert with the Boat Owners Association of the United States -- BoatUS -- notes that the rule of thumb for mixing resin and hardener is that four drops of hardener and 1 ounce of resin equals a 1-percent solution.

Cut two sheets of 1 1/2-ounce fiberglass mat the size of the plywood sheet, with a pair of shears. Cut two sheets of 6-ounce fiberglass cloth, the same size.

Spread the epoxy over the surface of the plywood that will face up, using a wide-blade putty knife. Lay a sheet of fiberglass mat on top of the epoxy and press the mat into the epoxy with the edge of the putty knife's blade.

Lay second coat of epoxy over the first and a sheet of the 6-ounce fiberglass cloth onto the epoxy. Again, press the glass cloth into the epoxy. Repeat and cover the last layer of fiberglass cloth with a coat of epoxy.

Allow the epoxy to dry, a process that usually takes 24 hours. Sand the top layer of epoxy flat with a 220-grit sandpaper. Paint the fiberglass, if desired, with non-skid marine paint, or an acrylic latex with crushed walnut shells -- an inclusion you can obtain at boating supply houses.

Position the deck panel in place in the boat. Drill 1/8-inch pilot holes in the corners of the panel with a drill and a 1/8-inch bit. Screw the panel into place using 3/8-inch self-tapping stainless steel screws and a screwdriver.