So....... I finished up the project
I followed the advice of the above esteemed posters (thanks guys

)
The board was cut to size and the old hardware mount holes drilled using the old board as a template.
Then it came time to lay the glass. I have never done it before. I found a video or 2 on YouTube and laid out my cloth and let it rest and smoothed until it went flat. Then I did the top which went really well and I was happy with the results.Then I found out I suck at doing/wrapping edges. I got to the point that I just painted the edges and 2-3 inches of the bottom edge with resin and called it good. After sanding it actually looked like a half decent job, I probably would have asked for a discount if I had paid to have someone do it, but for a first time I was fairly pleased.
The epoxy paint was a pretty straight forward affair. I coated the bottom in a layer, cured it and flipped it over. I laid the first coat on the top fairly heavy and then before it dried I applied my traction agent (the kids will never notice a cup of sand missing from the sandbox) with a hand held garden spreader set to it's finest setting. Coat two went on normal thickness and the whole thing got baked in my garage for 2 days in this lovely heat of ours.
Then came time to mount. The old screws were [censored] so I wanted to go heavier and/or better. SO after marking my stringers and my drill lines I laid the floor and drilled my first two holes. This worked like [censored]. the stringers were not strong enough to hold the threads of the screws. As soon as they got through the aluminum they just punched all the way down (since I already had the holes drilled I left them in a sealed them to the board with epoxy for additional lateral stability and to keep the holes filled). I ended up having to go with blind rivets. Problem was that I needed a long grip to go through the plywood,stringer, and epoxy. After tearing up the phone lines I ended up heading to Southerland's to get the appropriate fasteners. Since I was using pop rivets I ended up using more fasteners than I had planned on just to spread the load around more evenly but the results were really good.
In the end I have a great floor. I dropped a socket on it while I was installing my accessories and it sounded like it hit slate. The tread is fantastic and the fit is perfect. This was a lot of work, but I expect that it will be at least another 20 years before that floor needs to be done again.
Here are the pictures:
Finished floor
IMG_7421 by
fyoutoo, on Flickr
Non slip coating with a quarter for reference. Kinda blurry but you get the idea.
IMG_7422 by
fyoutoo, on Flickr
I sealed the rivet heads with epoxy paint. I wanted to seal the wood around the countersinks. One again quarter for reference
IMG_7424 by
fyoutoo, on Flickr
The screws I tried to use
IMG_7425 by
fyoutoo, on Flickr[/img]