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Type: Posts; User: drize

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    Thanks Michael for the tip. I did actually have...

    Thanks Michael for the tip. I did actually have a couple of rivets that that were hidden.

    I believe I purchased the carpet through ebay. It was a 20 oz rubber backed that matched the original...
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    I took measurements of the stripe before removal....

    I took measurements of the stripe before removal. A heat gun, acetone, and a little elbow grease did the trick. I like the clean look of the boat without the stripe that I may not put it back on....
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    Lid comes back down and ratchet straps help to...

    Lid comes back down and ratchet straps help to fit. Most of the prior holes lined up perfectly except for the front quarter. I am still baffled by this.
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    With the excepion of replacing starters, this...

    With the excepion of replacing starters, this boat has been pretty trouble free over the last 25 years. For better access to the starter in the future, I decided to use hinges to mount the motor...
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    Next project was the motor box cover. The...

    Next project was the motor box cover. The factory used butt joints and staples. Mine came out as more of a lap joint for a larger surface area for gluing.It was easier to cut the large angle by...
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    Top of floor gets glassed in. I did not allow...

    Top of floor gets glassed in. I did not allow for the thickness of the carpet when fitting in the inspection cover over the prop shaft. I had to trim the width then re-attach the carpet....
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    Another error is when fitting the floor, I cut...

    Another error is when fitting the floor, I cut out a square under the motor box. The floor is actually angled toward the front so I had to create an insert. Once again, more CPES....
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    Here are a few of the errors I made. I decided...

    Here are a few of the errors I made. I decided to replace the 1/2" factory flooring with 3/4" marine plywood. In doing so, I reduced the stringer height by
    1/4". This exposed the ski pylon...
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    Thanks for the comments guys. I started this...

    Thanks for the comments guys. I started this project 1 1/2 years ago but decided to post after completion. My job has me traveling through the week and family oblighations on the weekend made this...
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    Motor alignment was easier than I thought. ...

    Motor alignment was easier than I thought.

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    One of the sweet tips I learned from this forum...

    One of the sweet tips I learned from this forum was to use frezer bags and label everything. This really helped when putting her back together.The 3M 5200 is some good stuff.
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    I had to roll the boat out, lift the motor with...

    I had to roll the boat out, lift the motor with the chain falls, then roll here back in, to get the motor in. It fit pretty well.
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    One of my modifications was to reinforce the...

    One of my modifications was to reinforce the driver seat area and eliminate the foot well. I also eliminated the 'doghouse' and moved the bilge pump forward to the lower area. I also decided to...
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    Cross members are sanded and glassed into place...

    Cross members are sanded and glassed into place using PL adhesive.
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    The cross members also get the fiberglass...

    The cross members also get the fiberglass treatment before attaching.
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    The factory notched in the cross members and that...

    The factory notched in the cross members and that seems to be the point where the stringers start to rot. I decided not not to nothch and added extra cross members. I measured, cut, rounded and dry...
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    Time for the fiberglass process. I used West...

    Time for the fiberglass process. I used West Systems microfiber filler material and US Composits epoxy to make the 'peanut butter.' I decided on the 1708 glass mat also from US Composits....
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    Although the factory sandwiched 2x's together for...

    Although the factory sandwiched 2x's together for the motor box, I decided to use a solid piece of stock for mine. I had to measure the angle and sand off the excess.
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    I added drain holes since I am not replacing...

    I added drain holes since I am not replacing foam. I tacked in the stringers using PL adhesive with 1/8th inch shims and clamped into place. I was a bit too agressive with the adhesive and had to...
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    Everything gets soaked in CPES. The CPES will...

    Everything gets soaked in CPES. The CPES will eat through the red Solo cups eventually as I found out.
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    I used a compass as a scribe, a hand plane, and a...

    I used a compass as a scribe, a hand plane, and a belt sander to form the shape of the stringer.
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    Grinding out the area for the new stringer creats...

    Grinding out the area for the new stringer creats a lot of dust. Do not under estimate, dust gets everywhere. I rented this Milwaukee grinder but ended up buying a DeWalt variable speed...
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    There is a lot of discussion on what to use as...

    There is a lot of discussion on what to use as replacement material. I decided to go with Sitka Spruce from a special lumber store in Charlotte MI. It is Very Expensive but I love the straight...
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    I used my cut-off tool to cut out the stringer. ...

    I used my cut-off tool to cut out the stringer. I drove an eyelet into the stringer and attached it to the chainfall. It was heave but came out in one piece. The stringer was in pretty good shape...
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    Time for foam removal. The foam holds water as...

    Time for foam removal. The foam holds water as you can see here, especially in the 'doghouse'. I decided not to replace it.
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