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  1. #1
    Join Date
    Feb 2017
    Location
    Phoenix / Chicago
    Posts
    124

    Default 1986 Sunsport (open bow) rebuild

    Took on this project last summer. With school and work it's been slow coming but it'll get there.

    It's going to be a lot of extra work but I'm not doing carpet. I've gel coated all the visible surfaces and I'm planning on routing my own black on faux teak Seadek.




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    Last edited by Milliken37; 03-05-2017 at 09:21 PM.

  2. #2
    Join Date
    Feb 2017
    Location
    Phoenix / Chicago
    Posts
    124

    Default

    I knew I was getting into a lot of work but even at this point I had no idea.





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  3. #3
    Join Date
    Feb 2017
    Location
    Phoenix / Chicago
    Posts
    124

    Default

    Time to tear out some stringers! Woohoo!

    My number one suggestion to anyone wanting to take on a full rebuild is... Don't!






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  4. #4
    Join Date
    Feb 2017
    Location
    Phoenix / Chicago
    Posts
    124

    Default

    For the stringers I used 23/32 treated plywood. For the inner stringers I staggered the ends of the strips and then glued, pressed, and screwed them together.




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  5. #5
    Join Date
    Feb 2017
    Location
    Phoenix / Chicago
    Posts
    124

    Default

    I used 1.5oz mesh cloth, 1.5oz biaxial, and epoxy resign. Under the stringers I loaded it up with a mix of epoxy resign "peanut butter"

    I would suggest to anyone to use thinner mesh cloth, with more layers. Thinner cloth with contour better.

    Don't use polyester resign. It won't have the structural support that epoxy does.




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  6. #6
    Join Date
    Feb 2017
    Location
    Phoenix / Chicago
    Posts
    124

    Default 1986 Sunsport (open bow) rebuild

    I forgot to get picture of installing the foam under the floorboard.

    At this time I was supposed to head to Phoenix for school in 2 weeks so I was pressed for time.



    The brown on the sides is a strip of fiberglassing to keep water out of the voids during my trip.



    Improvising at its finest. Using the apartment complex carport as a check lift using ratchet straps


    Got the floor deck fiberglassed



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    Last edited by Milliken37; 03-05-2017 at 02:41 AM.

  7. #7
    Join Date
    Feb 2017
    Location
    Phoenix / Chicago
    Posts
    124

    Default 1986 Sunsport (open bow) rebuild

    At this point on I've been doing my work out of a storage unit at my apartment complex. Not ideal condition but I've been making it work.

    Fresh gel coat on the deck floor


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    Last edited by Milliken37; 03-05-2017 at 02:45 AM.

  8. #8
    Join Date
    Feb 2017
    Location
    Phoenix / Chicago
    Posts
    124

    Default



    For these edges, I did each surface separately. I hit the cloth with polyester resign, let it set for a day, then cut away the access.






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  9. #9
    Join Date
    Feb 2017
    Location
    Phoenix / Chicago
    Posts
    124

    Default

    Here I just wanted to see how everything sits and looks. I have yet to cut away slots in the fiberglass lip at the bottom to allow the seats to sit flush.

    I'm planning on fastening the lower engine surround with 2 stainless steel pinned hinges and 2 anti-rattle latches.

    I'll be fastening the seats with corner brackets and inset threads in the floorboard so that then can be unscrews and removed.




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  10. #10
    Join Date
    Feb 2017
    Location
    Phoenix / Chicago
    Posts
    124

    Default

    Can't wait to get the rest of the engine as shinny as that air filter and those valve covers.


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