The Refit Grind: How a 22kg Floor Fits Into a 600kg Weight Loss

/ Floors, Paikea Refit / By

Author: Shayne and Anna

Key Message: By replacing a heavy, non-structural plywood floor with a custom composite one, we achieved a monumental 75% weight saving in this area—transforming 30kg of dead weight into an 8kg structural component that actively strengthens the hull.

In boat building, every kilogram saved is a win. So, when we weighed the old, rotting plywood floor in our catamaran’s aft cabin and saw it was 15.23kg for just half the floor, we knew we had a massive opportunity. By replacing it with a custom-built, fibreglass composite floor and hatches, we achieved a staggering 75% weight reduction, turning dead weight into a strong, structural part of the boat.

The Weight Savings: By the Numbers

The results of this upgrade speak for themselves. We moved from a heavy, non-structural timber floor to a lightweight, fully integrated composite system.

The Data:

  • Old Half Floor Weight: 15.23 kg (marine plywood with vinyl topping and bracing)
  • New Full Floor Weight: 7.84 kg
  • Total Weight Savings: Over 22 kg for the complete aft floor area
  • Hatch Weight: Under 1 kg each

This means the entire new floor system—a complete floor and multiple hatches—weighs less than half of the original timber floor alone. This kind of weight reduction directly translates to better performance, improved fuel efficiency, and increased payload capacity for supplies.

The Build Process: Lighter and Stronger

The transformation wasn’t just about swapping materials; it was about redesigning the component to be part of the boat’s structure.

From Plywood to Composite:
The original floor was heavy plywood that simply sat in place, secured with a few screws. It provided no structural benefit to the hull. Our new floor is vacuum-infused with fibreglass, using a PVC foam core. Once laminated into the hull, it becomes a structural panel, actively contributing to the boat’s overall stiffness and integrity.

Iterative Hatch Design:
The project was also a lesson in iterative improvement. The first hatch we built was slightly heavier, using 1200g of material on both the top and bottom skins. By the final hatch, we had optimized the process, using a heavier skin on the walking surface (1200g) and a lighter, but still strong, skin on the bottom (700g), all while ensuring it was more than strong enough for a “small elephant” to stand on.

A Family Affair in the Workshop

With rainy weather outside, our boat’s saloon was temporarily converted into a laminating workshop. The project became a family effort, with the kids helping to clean up the newly infused hatches and manage the workspace. This hands-on involvement is a core part of our refit philosophy, turning a massive project into a series of manageable, family-oriented tasks.

Conclusion: A Lighter, Brighter Future

Replacing the aft floor is more than just a cosmetic upgrade; it’s a fundamental improvement to Paikea’s structure and performance. Shedding 22kg of dead weight from one area of the boat is a significant achievement. Combined with the new structural strength and the clean, modern finish, this project represents the very best of what a refit can achieve: a boat that is lighter, stronger, and better suited for the adventures ahead.

Continue following our refit journey:

Scroll to Top