The Floor Goes In.

1996 SD 16' rehabilitation. New floor. The previous floor was 1/4" (6.25mm) chipboard with fiberglass over top. We decided to go with 1/2" thick marine grade plywood where we could (upper level in back), or two layers of 1/4" marine grade laminated together (everywhere else).

Prepped upper area with all holes covered with fiberglass except for table leg receptacle holes.

Using paper to make a template.

Template on the 1/2" marine grade plywood. I marked out a few of the previous attachment holes to help with alignment. I drilled these in the wood too.

I set my jigsaw to a 30" angle. The edge of the plywood will match the fiberglass radius more easily this way. Also, for any areas of fine adjustment, then I can trim the edge off with a knife (since it will be a thin edge due to the angle).

Cut out.

I used a belt sander to feather out the edges a little more. note the three screws that I can use for alignment in the trailer.

After a few in and outs with the plywood, it fit well enough. the screwdrivers are through the plywood and in the old holes.

Note that I also drew the frame lines on the panel. This is so I can see them from inside the trailer when I am attaching things back to the frame for the placement of new screws.

I had mentioned the bathroom enclosure in another post. Back and forth it goes as I work in one area or another.

The lower area is 8'-6" long by about 5'-8" wide. So... can't be done with one sheet. I didn't like the seam in the previous flooring, so I decided to use 1/4" sheets of plywood cut to overlap each other.

Draw everything out! Measure twice... cut once. (If only I listened to that advice...)

Cutting out the various shapes to get the overlapping pieces.

In and out... in and out... getting that edge to the right outline, and feathered out below correctly to match the radius of the trailer fiberglass.

More feathering with the belt sander.

After enough test fits, the pieces fit well.

Fitting well.

Now... to plan out which pieces I can laminate before I take them in. The Casita door only allows certain sized pieces in!

Frame lines on the upper layer for future reference.

And... notes to NOT drill into the holding tank!!!

In order to laminate it inside, I wouldn't be able to clamp. So I predrilled a bunch of small holes so I could put 1/2" screws in to hold the layers together.

What I'm using for fiberglass work, for coating wood to waterproof it, and also to laminate the plywood.

I should also mention that before I fiberglassed the holes from the inside, I put some paper under the Casita. I didn't want to glue it to my garage floor.

Showing how the pieces go together.

Laying down epoxy to laminate the piece that goes above it.

Screwing the piece down to the one below it.

What it will look like together.

Showing how it comes apart. These are the two pieces I need to get into the Casita.

Coating the bottom and edges with epoxy to further waterproof the marine grade plywood.

Don't forget that it gets a shower pan and toilet!

The shower pan has a beveled edge to allow it to drain to center. Angle grinder with a sanding disc.

Putting the shower pan and black water tank on top for a test fit.

Further sanding based on test fit.

Here's what it looks like before the floor goes in.

This shows the bottom layers in place. They already had the side pieces glued onto them.

Adding epoxy before I add the central top piece.

Moving the central top piece into the Casita.

Last chance to look...

Top piece in place and being screwed down to set it into the epoxy and laminate it to the lower piece. Floor is in!!