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Discussion Starter · #1 ·
Finally got the decking on the new boat done.

The worst part was cutting the aluminum. I'm a wood worker and have no metal tools. I went through so many metal jig saw blades it was unreal. They just didnt last.

But I think it came out looking pretty good.
 

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Red X Angler
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Looks great!!. For reference you can buy a saw blade for a circular saw that cuts aluminum. Then you only have to use the jigsaw for details.
 

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Discussion Starter · #4 ·
Really appreciate the comment.

First of all...being in my mid 60's and a disabled Vet, an uneven "floor" is just asking for problems. But, I didnt want to add a ton of wood to the boat.

I couldnt find 1 1/2 inch rigid foam so I used two pieces of 3/4 inch foam between the ribs. On top of that I went to Tractor Supply Company...TSC....and got some 3/8 inch horse stall mat rubber that is 48 inches wide. Figured if horses could stand on it all day it had to be pretty durable. Notched the mat to fit the ribs and had to order from Grainger 4 inch wide, 1/8th inch thick aluminum flats. Four flats each 6 feet long set me back $108. Notched them too to the ribs and put just one screw in. I am waiting to see if the one screw suffices. On the front deck of the boat I was able to use aluminum from Lowes with no problem....didnt need four inches there.

Another bad part was etching the aluminum.....it doesnt rust but it corrodes....then sprayed it with pick up truck bed liner rubber. That was messy and a real pain.

But it all came out pretty good and I dont expect I will be tripping over an uneven "floor" ....deck.
 

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Discussion Starter · #5 ·
Looks great!!. For reference you can buy a saw blade for a circular saw that cuts aluminum. Then you only have to use the jigsaw for details.
It was a nightmare. I used Bosh blades and they were pure junk. But they were all I could find. I would take a 2X4 so to use the high part of the blade....then use a 3/4 inch piece of wood to use a different part of the blade....then just let the jig saw sit flat to use the last part of the blade.

No one cut was longer than an inch but each ate up a blade. Ive used other blades in the past and never got so little results. I am a fan of a lot of Bosh tools but these blades were very disappointing.
 

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Red X Angler
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I have found Bosch to be disappointing too. I use Milwaukee when I can find them otherwise just black and decker from Walmart if they aren't going to last might as well be cheap and easy to get LOL
 

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Discussion Starter · #8 ·
You did a good job.
For future reference, we could have kept you in the wood realm for the weight added there. glassed it , and coated it in KiwiGrip.

Di you use a variable speed saw?
I used a Makita jig saw....not variable.

Who be "we" ??

My total costs were about $200. What would the KiwiGrip and other stuff go for??
 

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Looks great!!. For reference you can buy a saw blade for a circular saw that cuts aluminum. Then you only have to use the jigsaw for details.
We cut aluminum parts at work with a carbide tipped blade in a miter saw, it cuts pretty clean and easily. Just buy a cheap blade or use and old one with the intention of throwing it away. A little air grinder with a cut off wheel works pretty good too.
 
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