Swim Platform Project

When we purchased Tropical Horizons we knew that the swim platform needed to be worked on. There were some dings from when the previous owner had the boat. The stock swim platform was quite narrow and my plan was to either extend the existing swim platform or build a new one. I wanted about double the width which would allow me to set a folding chair and table on the platform while I used the BBQ, and allow the use of a dinghy davit system as well.

The first step was to remove the swim platform after Tropical Horizons was hauled out for the winter. We had the boat yard do this then travelled down to pick it up with our trailer. At this time Tropical Horizons was being kept indoors at Turkey Point marina on Lake Erie. Karen and I headed down and when we collected the batteries (for winter storage and charging at home) we also collected the swim platform. This is where I decided that there was no way I was going to add anything to the existing platform as it was extremely heavy being made of solid fiber glass. We loaded the platform on our trailer and brought it home.

Once in my shop, I built a work table that would accommodate the existing and new swim platform. Once the table was built, I heaved the existing platform onto the table and with a black marker, traced out its contour along with the location of the mounting holes. Once I had the general outline of the existing platform, I then removed the existing platform and stored it under my work table. The next step was to draw the outline of the extension that I would be building. I had decided to build a cored platform in order to keep the weight down. I calculated how much core material I needed and decided to use a foam core product such as Divinicell. I also decided to add carbon fiber components to the high stress areas that would offer support to the platform, mainly at the attachment points and along the edges. The foam was purchased and I started work as long as I was able to warm the shop up to a good working temperature.

Foam structure complete and ready for carbon fiber.

The first step was to lay out the general deck and trim it according to the contour that I had traced on the table. To be clear the build will start upside down, with the laminating of the underside first then the laminating of the topside. I suppose I could have vacuum bagged the entire project but I really wasn’t equipped for that and I was trying to keep costs under control. Once the deck sheets were trimmed and in place I laid out a strip of plastic under each of the seams and glued the sheets together using a good quality carpenter’s glue. After the deck had set, I then started working on the edges, and finally the grid frame structure that would support the deck.

Frame work with mounting pads for supports, this is where I should have rounded the edges with a router.

Once the foam core structure was built, the laminating process started. I first started by laminating all of the carbon fiber reinforcement. Carbon fiber was laminated to the grid frame and the inside of the edges. Once the carbon fiber was laid up, I continued with the glass layup. The entire underside was laminated and allowed to cure. After the cure, the entire platform was turned over and the deck was faired and sealed prior to glass layup. The layers of glass were laid up on the deck and once again allowed to cure.

laying carbon fiber tape

Applying resin, should have used resin with filler first to avoid dry patches

Fully cured and ready for glass cloth

Again should have applied thickened epoxy first then the glass

Glass layers cured, adding carbon fiber to edges.

Underside cured and complete.

Ready to flip over.

Flipped over and fairing begins. Notice the routed edge.

Surface and edges are fair and ready for glass.

This time I applied thickened epoxy first.

Glass layers applied.

After the glassing of the swim platform, I then sealed the entire project with a 2 part epoxy primer on each side. After the primer was applied, I then applied a 2 part polyurethane paint on the deck in two coats. Finally with the swim platform finished, we transported it back to Tropical Horizons and installed it during our spring commissioning.

Priming begins, really nasty stuff, the respirator is not just for fun.

The green gives way to a cream color, that I thought matched the boat well.

All done, 1 coat of primer and 2 coats of paint.

That year we had quite a list of items to complete before we started our journey across Lake Erie and through the Welland canal.

Lessons learned with this project.

• Use epoxy to glue foam core together. The carpenters glue did work but I think the epoxy would have yielded a much better bond in the end.
• Radius all edges with a router. I only figured this out when I laminated the deck and it made a big difference on the application of the laminates.
• Prior to any lamination seal the entire surface on the foam structure with thickened epoxy to avoid having the epoxy seep through the glass cloth and down the underside of the project. You can layup while the thickened epoxy is still sticky.
• When working the underside, work small sections at a time.
• Where holes are to be drilled, remove coring and used solid laminates.
• Bring in a piece of the original platform for color matching.

Would I ever attempt this again? Most likely but armed with what I know now I would be far more patient. How did the project turn out? Not bad considering this was my first real large scale project using foam core and carbon fiber.