- 1). Measure the shape of the floor on your aluminum boat where the plywood will be installed. Record all measurements for the length and width. Lay a sheet of 3/4-inch plywood down on a flat surface and outline the shape of the boat so the plywood can be cut to size.
- 2). Sweep up the aluminum along the floor of the boat with a broom and dust pan. Pick up all larger dirt and debris from the area so the plywood will sit flat on the surface and can be installed flush with the floor.
- 3). Line up the blade of a circular saw with the mark on the plywood. Run the blade along the mark on the plywood until the exact shape is cut out. Turn off the blade of the saw and set the piece of plywood in the boat to verify it fits properly.
- 4). Seal the plywood with an epoxy. This will help keep the plywood in good condition even when it gets wet. Spread out the epoxy with a paint brush over the entire surface and let it dry for one hour. Flip it over and seal the back and all of the sides in the same manner.
- 5). Turn the plywood so the bottom side is facing up and spread out construction adhesive over the entire surface. Use a trowel to cover the area with a 1/8-inch thick layer and set the plywood on the aluminum floor. Run your hands over the entire surface so the adhesive can adhere to the plywood and the aluminum.
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