The 2002 Active Thunder 37 Excess has a reputation as a high-performance powerboat that combines speed, agility, and eye-catching design. However, as with many performance boats of this era, owners have experienced recurring challenges over time. From unstable handling at high speed to aging deck materials, these issues can impact safety, comfort, and overall enjoyment on the water.

This comprehensive guide will dive into the most common problems faced by owners, practical solutions, and how modern upgrades—like custom EVA foam flooring—can enhance your boat’s performance and onboard experience.

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1. Unstable Handling at High Speed

The Issue

Owners frequently report that the 37 Excess can feel unstable or “loose” when navigating rough water at high speeds. Even with sufficient engine power, the hull sometimes struggles to maintain proper water contact, causing the boat to bounce or shift unpredictably.

Key contributing factors include:

• Hull design tuned for top-end speed, which may reduce mid-speed stability.

• Incorrect propeller selection for the engine and load.

• Weight distribution with heavy items toward the stern.

Solutions

1. Propeller Adjustment
   Choosing a propeller optimized for mid-range performance rather than peak speed can significantly improve handling. Look for:

   • Slightly larger blade area

   • Pitch adjusted for acceleration and rough-water stability

2. Trim and Drive Height
   Proper adjustment of drive height and trim can prevent excessive stern lift and reduce “porpoising” in waves.

3. Weight Distribution
   Shift heavy items toward the center or forward. Batteries, water tanks, and gear storage should be balanced to maintain optimal hull contact.

Pro Tip: Regular test runs in various sea conditions can help fine-tune your settings.

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2. Powertrain Optimization Challenges

The Issue

Despite the 37 Excess’s high horsepower engines, owners report that raw power does not always translate to smooth acceleration or efficient performance. Symptoms include:

• Delayed throttle response

• Vibration at high RPM

• Excessive fuel consumption

Solutions

1. Complete Powertrain Matching
   Ensure that engine RPM range, gear ratio, and propeller pitch are aligned. This creates smoother power delivery and reduces strain on the drive system.

2. Inspect Drive Components
   Bearings, universal joints, and couplers should be checked and replaced if worn. A well-maintained drive system significantly improves throttle response and handling.

3. Hydraulic Steering and Mounts
   Tight and properly aligned steering systems prevent erratic movement at high speed.

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3. Interior Space and Added Weight

The Issue

Some 2002 models include interior liners, custom seating, and added structural supports for comfort. While these upgrades enhance livability, they can also:

• Increase total weight

• Reduce usable cabin space

• Affect hull trim and performance

Solutions

1. Lightweight Alternatives
   Replace heavy seats, flooring, or cabinets with lighter materials. Modern marine composites and EVA foam can reduce weight without sacrificing durability.

2. Redistribute Storage
   Keep heavy items centralized to prevent stern lift and improve performance.

3. Optimize Battery and Tank Placement
   Placing batteries, fuel, or water tanks toward the center balances the hull and reduces bow or stern pitch.

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4. Aging Electrical and Structural Components

The Issue

As a boat approaching 25 years old, electrical and structural issues are common. Problems may include:

• Worn wiring harnesses

• Faulty pumps and switches

• Moisture intrusion around hatches and through-hull fittings

• Deck surface wear

Solutions

1. Electrical Upgrade
   Replace aging wiring, connectors, and switches to ensure reliability and safety.

2. Seal Deck Hardware
   Reapply marine-grade sealants around hatches, cleats, and through-hull fittings.

3. Check Structural Integrity
   Inspect stringers, transom, and core materials for moisture or fatigue. Address any water intrusion promptly to prevent long-term damage.

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5. Slippery and Worn Deck Surface

The Issue

Original deck surfaces may become slippery and uncomfortable over time, increasing the risk of slips and reducing onboard comfort.

Solutions

Custom EVA Foam Flooring is the modern solution:

• Provides excellent grip even when wet

• Reduces fatigue on long trips

• Offers heat resistance and comfort

• Can be custom-cut to fit your deck precisely

For the 2002 Active Thunder 37 Excess, you can explore custom flooring for a 2002 Active Thunder 37 Excess.

For other boat models, check custom boat flooring by brand to find tailored options.

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6. Routine Maintenance Tips

Even with upgrades, routine maintenance ensures longevity and safety:

• Inspect and lubricate the propulsion system every 6–12 months

• Test steering and trim systems before each season

• Check for moisture in core panels and stringers

• Monitor engine performance and fuel efficiency

By combining preventive maintenance with thoughtful upgrades, owners can maximize the boat’s performance and comfort.

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7. Final Thoughts

The 2002 Active Thunder 37 Excess remains a top choice for enthusiasts who value speed and design. While older models have predictable issues, careful adjustments, modern upgrades, and routine maintenance can transform this classic high-performance boat into a safe, comfortable, and exciting vessel for years to come.