Sport 165 Floor rebuild

[btuell]

Inspired by Greg58, I decided to repair the floor of a used Sport 165 I purchased in Feb. In the cold Michigan winter, I failed to see that which the unscrupulous seller declined to tell me about. A water damaged OSB floor in the bathroom and under the water heater. Found it when I was starting to prep the camper once spring broke. So I wanted to share pics of my adventure and hope it gives some insight you can use to work on yours. These first few pics shows the issue I’m dealing with. You can see how he tried to find a matching piece of linoleum to cover his tracks. I should have known when I saw the metal threshold as you enter the bathroom that something wasn’t right. Hoping karma has him in the end as the kids now have to wait for our camping trip to the UP.

[btuell]

Started to tear out the old floor here. Used a circular saw to score it without cutting the underlayment. Multi tool to get wet wood from under the back wall. Cut the side walls flush as wood wasn’t as bad there. Careful of the screws coming into the floor from outside the back wall along the bottom. They have a plastic screw cover back there. Easy enough to remove those screws except for the one behind the spare tire. Was rusted and broke off from the inside anyway for me. Found more wet wood in front of the bathroom so had to keep going.

[btuell]

Had to take apart quite a few things to get at the floor. Electrical wall that is part of the bed frame had to come up. I screwed all around that. Unhooked the 30amp cord from the electrical box and shoved that back out the back wall. Had to unscrew the black pipe draining the tub and cut it off under the bed. Unhooked the wires coming out of the floor under the bed from the fuse box. Also had to cut the wires coming out of the floor under the tub and sliced into the main wiring harness. Will have to get new connectors to put those back together. Tub was easy to unhook from the drain if you get at it from under the bed and remove that access wall to the tub area. Took off the shower wall and removed the toilet.

[btuell]

Decided to go with sanded plywood and painted both sides with Zinsser Oil based primer And Rustoleum oil based black paint for protection and a smoother surface. Was a puzzle to figure out how to fit the biggest pieces I could into those tight awkward spots. Had to stick to where the floor rails were and I could t get real close to the side walls so really only screwed on the rails going side to side vs front to back. Using Teks self drilling screws for wood to metal. Using the right drill bit, seems to work pretty well. Used to small of a bit at first and stripped the head of a few screws. You can see my puzzle pieces, you may have a better idea for yours. Used a crow bar to lift that bed/bath wall to get those pieces under. Look out for hidden screws going from the wall into the floor.

[btuell]

Decided to repaint everything since I’ve got the floor apart. Washed, lightly sanded and used Krylon to give the tub, shower, toilet, tub faucet, shower head, kitchen sink, kitchen faucet a fresh coat of white paint. Will be painting the cabinets white, countertop grey, and ceiling a new coat of white to freshen up. Plan to find a good paint for fabric and paint the window coverings, couch cushions etc black to match. May need to sew new covers for the cushions, will see. Also found this nice vinyl planking that clicks together with no glue or underlayment needed at Menards. 4mm thick so not too much weight added. I think I’ll use that to put a new floor down since I had to cut the old linoleum up.

[Tiguan Tow r]

Nice Job! Thanks for the pics and detailed explanation. Well done.

[Sport165]

Great job!
I have same TT, 2004, what year is yours?
Also, Please share more pics when you complete your remodel

[btuell]

Bought a Wagner spray painter and painted the entire interior, walls, cabinets and ceiling. Taping off everything was a chore and I didn’t do it perfectly but I’m happy with how it turned out. The kitchen faucet broke on me so I found a used kitchen faucet in marketplace. For very nicely although it’s much heavier. I installed a new floating floor, the vinyl planks that snap together. Turned out great but was a lot of cutting. I added shoe molding to finish it off. Also replaced the metal holder the table pole slides into and am much happier with the stability. Got that off of amazon.

[btuell]

More pics...

[btuell]

It’s a 2008 165 Sport. Perfect size to take up to the UP here in Michigan. Really looking forward to exploring in this one!

[TCNashville]

That is some really nice work! Well done.

[Sport165]

Terrific job ��