Cory's fiberglass boat resto (with pics and info)

colsoncj · 04-03-2005, 09:21 PM

Well I've started my first fiberglass boat resto. Its a 17' Duo sportster... I love it to death.. We're puttin in a new floor, new transom and fixing up the 100hp johnson on the back. I should have pics up soon!!!

EDIT: For pics please go here now (with the exception of those already posted on this page):

http://pk-designs.com/album.php?link...age=1&numpp=12

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alanbobalan · 04-03-2005, 09:22 PM

Sweet!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

colsoncj · 04-03-2005, 09:22 PM

Well today we stripped out the interior and the floor, and took it on a madien voyage with some paddles and a case of beer... to check for leaks of course.

alanbobalan · 04-03-2005, 09:25 PM

damn, i want some beer.

colsoncj · 04-03-2005, 09:36 PM

Ok, heres some of the guts ripped out. We cut the lines to the outboard, removed it off the transom. Next we pulled out all the lose junk in the boat. Next we yanked out the seats with brute force (no need to save the floor) , they are attached with four screws that you can remove if you want. Then we removed all the side trim panels, again by brute force, if you want to nicely remove them, they are attached with screws from the backside, reach in up and around and you can get to them... Finally it was remove the flooring... we started at the rotted out section and just started yankin out flooring, we also used the claw end of a hammer to pry out pieces, and a shovel to pry, and remove the pieces. it took 1 55gallon drum and 2 26 gallon drums full to haul the stuff off.

heres some pics of the stuff removed and the inside of the hull:

colsoncj · 04-03-2005, 09:37 PM

As soon as we round up a better camera, there will be better pics, and pics of the boat itself.

colsoncj · 04-03-2005, 09:46 PM

Lemme know what you guys think!

stevrock · 04-04-2005, 02:09 AM

I just found my next update for project supra

Tacoma Dude · 04-04-2005, 02:15 AM

You're making me reconsider a decision I made a few weeks ago to not look into a free boat and trailer off of Craigslist in San Diego. Looked like crap but hey it was free!

Dang, should have picked it up! :pat:

Ironmike4x4 · 04-04-2005, 07:27 AM

Quick question hijack..... how do you restore the paint color on the boat? My Uncle gave my dad (to give to us) a 17' Thundercraft boat and the outside 2 tone paint on it has faded to a cloudy grey color. Also is there anyone that sells a foot for the propeller? I was showing off for a few girls in the boat one summer and stripped the foot gear on it so all I had was reverse and a high rev in foward.

colsoncj · 04-04-2005, 02:48 PM

For the paint color, most likely its a gel coat. (Im assuming its fiberglass). Gel coats like to fade, all do eventually. You have two options, 1) take some polishing compound and clean it up with that, then wax over it (does an ok job, but won't be looking like brand new) or 2) re gel coat it... (which is a boat load of work, but doable by the DIY'er. Search around on this site : www.classicmako.com and search the forums for info, there is a wealth of knowledge on the site, even for other boats. And feel free to hijack this thread for Q's about boat repair.

Peter, you should have gotten that boat man, free stuff is free stuff.

colsoncj · 04-04-2005, 03:28 PM

As for the outboard, I don't know much about them, I leave that to the marina. We've got a marina close to me that does a tune up, fluid change, lake test and tune, and minor get it ready fixes all for 150... which i consider money well spent.

Ironmike4x4 · 04-04-2005, 06:37 PM

Quote:

Originally Posted by colsoncj

As for the outboard, I don't know much about them, I leave that to the marina. We've got a marina close to me that does a tune up, fluid change, lake test and tune, and minor get it ready fixes all for 150... which i consider money well spent.

Oh ok thanks for the suggestions about the paint too, yes it's fiberglass but I wasnt sure if you could maybe polish it back since I dont know the effects of lake water on painted fiberglass. Thanks again!

colsoncj · 04-04-2005, 07:29 PM

No problem, give the polishing compound a try, you never know. If you do, remember you must wax it, because that will seal the gel coat and retard the oxidation which causes it to look like it does. And like I said, everyone is welcome to hijack this thread for questions!!!!

colsoncj · 04-04-2005, 07:32 PM

Huge progress was made on the boat today!!! We seperated the upper cap from the hull and opened everything up to help the resto... Basically, we pulled the trim off all around the sides of the boat, drilled out all the pop rivets and pulled the top of the boat off the hull and sides of the boat. I've got loads of pictures with a good camera, and as soon as I get them on my computer I'll post them!!!

colsoncj · 04-04-2005, 08:08 PM

Ok, due to the huge amount of pictures this thread will contain, I've moved all the pics to here:

http://pk-designs.com/album.php?link...age=1&numpp=12

The same link is in the first post.... When I update it, i'll post it when i give a description of whats goin on!!!

colsoncj · 04-05-2005, 07:31 PM

Well tonight we had a huge rash of severe storms, lots of hail, and high winds... the truck is fine, but I have yet to check on the boat.... hopefully this didn't set progress back. All materials have been ordered, and I found a pic of what the hull and cap will look like when done... the verdict is blue hull, white cap, blue interior.

Here's the pics (this boat is smaller than mine length wise, but same style):

Rivalred · 04-05-2005, 08:14 PM

That is one heck of a free deal...

Jeffires · 04-05-2005, 08:30 PM

That looks great- what year is your Johnson you mentioned? We've always had Johnson outboards....

colsoncj · 04-05-2005, 08:42 PM

Keep in mind the pics of that hull are not pics of my hull (at least it doesn't look like that yet :-)

the johnson is a 100hp ~1970.... Anyone know anything about this thing?

Jeffires · 04-05-2005, 08:55 PM

Does it say "Electric Seahorse" on it? We have a couple from the '60 that are very reliable and we still use. Yours may be a V4 or ESL, but I'm too young to know all those models and engine specs that far back. All I know is my dad has been running them in salt water and mud since then and they are still great motors.

colsoncj · 04-05-2005, 11:02 PM

I know its a V4, and I have a spare block... I'm pretty sure its going to be a good, motor, but I'd like to find a wiring schematic and what type of gas to use (Im 99% sure its a 2 stroke)

Jeffires · 04-06-2005, 07:05 AM

The V4 is a pretty tough design, I'd bet its 2 stroke (I don't even know if they had 4strokes back then). See if you can find a S/N to match it up on Johnson's website. See if you have an ESL model (electric shift) because you may have to find parts if it ever gets stuck in gear (they hang sometimes after sitting up). Johnson probably has schematics, if not, eBay has a variety of service manuals to choose from. I picked one up for my '67 40hp Evinrude a few months ago.

colsoncj · 04-06-2005, 03:56 PM

Sweet thanks Jeff!!!! Much appreciated!

Update of boat: Still rainy, so no work is getting done, however, I did pick up all the fiberglass resin and matting for it... Grand total for everything in it so far: 590 bucks. Not bad.

colsoncj · 04-09-2005, 12:58 AM

Well, no more work done yet, but i did order more parts. Got two brand new seats, and a bilge pump... great deal on them. heres the site:

http://www.boatersworld.com/webapp/w...atalogId=10051

Slowly but surely, we're gettin there!

04-03-2005, 09:22 PM	#2 (permalink)
alanbobalan Registered User Join Date: Oct 2004 Location: chino hills, ca Posts: 330	Sweet!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! __________________ EL TRUCKO THE X-WING FIGHTER 94 2wd pickup 22-re 5 spd 28 mpg el trucko kills tie fighters and soccer moms. MR TACO 98 tacoma 4x4 sr5 3.4 v6 5 spd stock with 31s mr taco, you were a great pal. may you live long and prosper. THE MILLENIUM FALCON (R.I.P.) 87 4runner efi sr5 ummm rolled over with lots of junk that i wasted my money on.

04-03-2005, 09:22 PM	#3 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	Well today we stripped out the interior and the floor, and took it on a madien voyage with some paddles and a case of beer... to check for leaks of course. __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

04-03-2005, 09:25 PM	#4 (permalink)
alanbobalan Registered User Join Date: Oct 2004 Location: chino hills, ca Posts: 330	damn, i want some beer. __________________ EL TRUCKO THE X-WING FIGHTER 94 2wd pickup 22-re 5 spd 28 mpg el trucko kills tie fighters and soccer moms. MR TACO 98 tacoma 4x4 sr5 3.4 v6 5 spd stock with 31s mr taco, you were a great pal. may you live long and prosper. THE MILLENIUM FALCON (R.I.P.) 87 4runner efi sr5 ummm rolled over with lots of junk that i wasted my money on.

04-03-2005, 09:36 PM	#5 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	Ok, heres some of the guts ripped out. We cut the lines to the outboard, removed it off the transom. Next we pulled out all the lose junk in the boat. Next we yanked out the seats with brute force (no need to save the floor) , they are attached with four screws that you can remove if you want. Then we removed all the side trim panels, again by brute force, if you want to nicely remove them, they are attached with screws from the backside, reach in up and around and you can get to them... Finally it was remove the flooring... we started at the rotted out section and just started yankin out flooring, we also used the claw end of a hammer to pry out pieces, and a shovel to pry, and remove the pieces. it took 1 55gallon drum and 2 26 gallon drums full to haul the stuff off. heres some pics of the stuff removed and the inside of the hull: __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

04-03-2005, 09:37 PM	#6 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	As soon as we round up a better camera, there will be better pics, and pics of the boat itself. __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

04-03-2005, 09:46 PM	#7 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	Lemme know what you guys think! __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

04-04-2005, 02:15 AM	#9 (permalink)
Tacoma Dude Contributing Member Join Date: Mar 2003 Location: Orange County, CA Posts: 8,360	You're making me reconsider a decision I made a few weeks ago to not look into a free boat and trailer off of Craigslist in San Diego. Looked like crap but hey it was free! Dang, should have picked it up! :pat: __________________ Peter! 2002 Tacoma 1986 4Runner

04-04-2005, 02:48 PM	#11 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	For the paint color, most likely its a gel coat. (Im assuming its fiberglass). Gel coats like to fade, all do eventually. You have two options, 1) take some polishing compound and clean it up with that, then wax over it (does an ok job, but won't be looking like brand new) or 2) re gel coat it... (which is a boat load of work, but doable by the DIY'er. Search around on this site : www.classicmako.com and search the forums for info, there is a wealth of knowledge on the site, even for other boats. And feel free to hijack this thread for Q's about boat repair. Peter, you should have gotten that boat man, free stuff is free stuff. __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

04-04-2005, 03:28 PM	#12 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	As for the outboard, I don't know much about them, I leave that to the marina. We've got a marina close to me that does a tune up, fluid change, lake test and tune, and minor get it ready fixes all for 150... which i consider money well spent. __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

04-04-2005, 07:29 PM	#14 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	No problem, give the polishing compound a try, you never know. If you do, remember you must wax it, because that will seal the gel coat and retard the oxidation which causes it to look like it does. And like I said, everyone is welcome to hijack this thread for questions!!!! __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done. Last edited by colsoncj; 04-04-2005 at 08:12 PM.

04-04-2005, 07:32 PM	#15 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	Huge progress was made on the boat today!!! We seperated the upper cap from the hull and opened everything up to help the resto... Basically, we pulled the trim off all around the sides of the boat, drilled out all the pop rivets and pulled the top of the boat off the hull and sides of the boat. I've got loads of pictures with a good camera, and as soon as I get them on my computer I'll post them!!! __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

04-04-2005, 08:08 PM	#16 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	Ok, due to the huge amount of pictures this thread will contain, I've moved all the pics to here: http://pk-designs.com/album.php?link...age=1&numpp=12 The same link is in the first post.... When I update it, i'll post it when i give a description of whats goin on!!! __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

04-05-2005, 07:31 PM	#17 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	Well tonight we had a huge rash of severe storms, lots of hail, and high winds... the truck is fine, but I have yet to check on the boat.... hopefully this didn't set progress back. All materials have been ordered, and I found a pic of what the hull and cap will look like when done... the verdict is blue hull, white cap, blue interior. Here's the pics (this boat is smaller than mine length wise, but same style): __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

04-05-2005, 08:14 PM	#18 (permalink)
Rivalred Registered User Join Date: Jul 2004 Location: Michigan Posts: 1,390	That is one heck of a free deal... __________________ Traded in: 2005 Tacoma DC PreRunner SJ Package Silver Streak Mica Traded in: 2007 Camry LE Silver

04-05-2005, 08:30 PM	#19 (permalink)
Jeffires Registered User Join Date: Aug 2004 Location: New Orleans, Louisiana Posts: 682	That looks great- what year is your Johnson you mentioned? We've always had Johnson outboards.... __________________ -Jeff- '91 4WD P/U 3VZE A340H , 197K K&N air ] Optima ] Flex-a-Lite fan ] FloPro exhaust ] ISR Mod ] Warn M8000 ] Powertrax lockers ] Swaybar Discos ] KC Lighting ] Premier MP3 - Pioneer highs/mids - RF DVC 12/ RF 360a² ] Garmin GPSMap60C Photo Album MySpace La Nouvelle-Orléans 'da Ragin Cajun

04-05-2005, 08:42 PM	#20 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	Keep in mind the pics of that hull are not pics of my hull (at least it doesn't look like that yet :-) the johnson is a 100hp ~1970.... Anyone know anything about this thing? __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

04-05-2005, 08:55 PM	#21 (permalink)
Jeffires Registered User Join Date: Aug 2004 Location: New Orleans, Louisiana Posts: 682	Does it say "Electric Seahorse" on it? We have a couple from the '60 that are very reliable and we still use. Yours may be a V4 or ESL, but I'm too young to know all those models and engine specs that far back. All I know is my dad has been running them in salt water and mud since then and they are still great motors. __________________ -Jeff- '91 4WD P/U 3VZE A340H , 197K K&N air ] Optima ] Flex-a-Lite fan ] FloPro exhaust ] ISR Mod ] Warn M8000 ] Powertrax lockers ] Swaybar Discos ] KC Lighting ] Premier MP3 - Pioneer highs/mids - RF DVC 12/ RF 360a² ] Garmin GPSMap60C Photo Album MySpace La Nouvelle-Orléans 'da Ragin Cajun

04-05-2005, 11:02 PM	#22 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	I know its a V4, and I have a spare block... I'm pretty sure its going to be a good, motor, but I'd like to find a wiring schematic and what type of gas to use (Im 99% sure its a 2 stroke) __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

04-06-2005, 07:05 AM	#23 (permalink)
Jeffires Registered User Join Date: Aug 2004 Location: New Orleans, Louisiana Posts: 682	The V4 is a pretty tough design, I'd bet its 2 stroke (I don't even know if they had 4strokes back then). See if you can find a S/N to match it up on Johnson's website. See if you have an ESL model (electric shift) because you may have to find parts if it ever gets stuck in gear (they hang sometimes after sitting up). Johnson probably has schematics, if not, eBay has a variety of service manuals to choose from. I picked one up for my '67 40hp Evinrude a few months ago. __________________ -Jeff- '91 4WD P/U 3VZE A340H , 197K K&N air ] Optima ] Flex-a-Lite fan ] FloPro exhaust ] ISR Mod ] Warn M8000 ] Powertrax lockers ] Swaybar Discos ] KC Lighting ] Premier MP3 - Pioneer highs/mids - RF DVC 12/ RF 360a² ] Garmin GPSMap60C Photo Album MySpace La Nouvelle-Orléans 'da Ragin Cajun

04-06-2005, 03:56 PM	#24 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	Sweet thanks Jeff!!!! Much appreciated! Update of boat: Still rainy, so no work is getting done, however, I did pick up all the fiberglass resin and matting for it... Grand total for everything in it so far: 590 bucks. Not bad. __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

04-09-2005, 12:58 AM	#25 (permalink)
colsoncj Contributing Member Join Date: Jun 2004 Location: Monett, MO (Springfield) Posts: 2,533	Well, no more work done yet, but i did order more parts. Got two brand new seats, and a bilge pump... great deal on them. heres the site: http://www.boatersworld.com/webapp/w...atalogId=10051 Slowly but surely, we're gettin there! __________________ Cory Eastern OK, Western/Northern AR, Southeastern KS, or Southern MO area: OZARKS 4ROC Click Here 04 Dodge 2500 Cummins - DD/Tow Rig 02 Z06 Corvette - Weekender 94 FZJ80 - Wheelin Rig. Build in progress: http://ttora.com/forum/showthread.php?t=129727 72 Buick GS - i.e. the project that will never get done.

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