1972 19' 1" Gull Aquasport rebuild- finally back at it

[Tim/GA]

Well, after over 9 months off I am finally back at work on the boat.  Have most of the demo done.  As you can see by the pics, the inner stringers and floor are gone and will soon have the last part of those stringers out and finish grinding the inside of the hull.  Also will have to strip the glass off the inside of the transom as it is cracked and have one suspect spot to look at inside the transom.

Boat had a slow lead along the starboard chine but when I got down to the bare hull there is no crack or damage showing.  It just looks like the glass in that area might be a bit porous.  I am planning on reinforcing the chines from the inside with a strip of biaxial tape.  Then after a bit of work on the outside stringers I am going to lay a layer of biaxial across the complete hull bottom and up and over the outer stringers.  I will also reglass the inside of the transom at that time.

Next will be replacing the inner stringers.  I am going to use forms to make the stringers, glass them in the hull and fill with foam.  I am going to lay the floor on the edges of the old floor to raise it slightly, so the stringers will also be slightly taller.

More later, but if anyone has any ideas, suggestions or cautions for me- please let me know!

[JimCt]

The original stringers are shot?

[Tim/GA]

Yep.  Some idiot decided to put in a large underdeck aluminum fuel tank.  Since the thing did not fit between the stringer, this brilliant person cut each of the two middle stringers right down the middle.  These were the glass over foam stringers.  They did not even bother to seal what was left of the stringers!  Besides that, I needed to reach the hull from the inside to lay the new glass over the chines and they were under the stringers.  

The stringers up under the front deck are fine so I will tie into those and I had hoped to do the same at the transom but since I need to re-skin the transom I might as well put new stringers up to the transom.

[JimCt]

Some of the homemade engineering that is done on these boats is incredible.  Bad engineering comes from the factory too which I'm in the process of discovering with my re-build.  Good to see you're "back on the job" with the restoration.

[billh1963]

Tim,
Glad to see you're at it!

My 1974 19-6 is under the knife as well. It's getting new decks, "rebuilt console", new wiring, new paint, a new leaning post with livewell, etc.

My thread will be updated with new pics later this week....

[Tim/GA]

Sorry for the long time before the update.  Hate to say I don't have many pics, working alone and either don't think about taking them or am just to hot and messy to take pics.  The heat has been a killer here in Coastal Georgia- glad I have SLOW hardner!  First time using stuff from US Composites, very good prices and I really like their resin.  It is thin and the slow hardner has plenty of pot life, even in 92+ weather.

Finally finished the demo on most of the boat, had hoped not to have to do anything with the transom but at the very least will need to reskin the inside or it.  I am hopeful that is all that will need doing.  Problem was that I had wanted to do the new stringers in one piece but since I might have to take out the transom I need some strength back in the boat.  Decided to put in the new, taller stringers and build up the side stringers, then deck that part of the boat to stiffen in up.  Then work on the transom.

At this point I have:
Layed a layer of 1708 biaxial over the old outer stringers (built up to the new height) and over the bottom of the hull.  Might have been a waste of resin to do it, but I can feel the hull is a good bit stiffer even without the stringers.  Also taped the chines prior to this.  

Built the stringers, used 1/4 Luan for the forms.  Used 9 oz cloth and 1708 to encapsulate the forms.  Filled with foam and tabbed in the boat.  First tabbing was 4" tape, then 6" 1708 biaxial tape (I cut) and the final was a full layer of 1708 over the complete stringer and 2" passed the other tape already layed in.  Stringers have 1/4 plywood, 2 layers of 1708 and 1 layer of 9 oz. cloth.

Tomorrow I will put in the bulkheads/frames.  Then lay the deck over the forward part where the new stringers are installed.  After that I should be able to finish the demo on the stern.

[JimCt]

Big progress & looks good.!

This is the stage where you really want to work out what plumbing, drains, thru-hulls and wiring chases need to go in, and where, before she gets closed up.

[Tim/GA]

Yep, those will be going in tomorrow along with the bulkheads, since they will run through them.  I am going to lay 2 rigging tubes along the starboard side and 1 along the port side, running from the console to compartments that will be built later along the stern.  The starboard one for the batteries and on the port side an oval livewell.

I know alot of people locate the batteries under the console, but since my fuel tank will be forward/ midships and the conole is pushed forward and partially sits on the front casting deck I think I might need the weight in the stern.  Any thoughts?

The thru hulls will wait a bit as they are going under the deck in the part that I am not going to be laying right away.  I also have to put in the fuel tank platform but I think I might wait and do that after the deck is down- not sure yet.

Oh yeah, just saw that we hit 97 degrees today- knew it was a HOT one!  Figure I have downed a gallon and a half so far today

[RickK]

Lookin' good - brings back memories, not only about the heat but rebuilding the stringers.
She'll be strong, that's for sure.  The wood in the stringers will give you more to screw down into for console, top or whatever, without having to add backer plates to the deck (at least in those spots).

[Kaczki]

My grandfather always had the fuel tank underneath the console and the two batteries in either back corner on my 19-1.

[RickK]

My grandfather always had the fuel tank underneath the console and the two batteries in either back corner on my 19-1.

Mine too.

[Tim/GA]

Built the rest of the bulkhead forms today and layed out the rigging tubes from the console back as far as I am going to be laying the deck at first.  Will have to extend them when I am ready to lay the back stringers and deck.  A 3" and a 1 3/4" tube on the starboard and and a 1 3/4" tube on the port side.  Also a 2" tube from the fuel tank compartment that will pass through the starboard stringer later- for the fuel line.  Inner and outer glass is curing on the bulkheads.  Going to template and cut the plywood for the deck in the morning so I can tab in the bulkheads and rigging tubes and lay 6 ounce glass (along with some backing plates for mounting the console, leaning post and seat) on the bottom of the deck pieces.  



Not sure how I am going to deal with the edges of the decking for the fuel tank compartment.  Any tips to make it look good?

Oh yeah, the batteries.  Most likely going to put them in a compartment (to be built) in the starboard stern.  That way I can build in a livewell on the port side stern.  The rigging tubes will also be coming up through the deck into an part of that compartment.  At least that is the plan for right now!

[Tim/GA]

No pics today, rain caught me right at the end.  A week in upper Michigan and then moving Mom from Ohio to FL meant a 2 week break from the boat.  School (high school math teacher) starts for me this Tues. so only a few more days to get some work done and wouldn't you know it- I need supplies.  That is what I get for not ordering while I was gone.  Thought I would run out of resin first but have about a gallon left (out of 7 1/2 from the last order) but am out of cabosil for putty to lay the fillets.  Might be able to squeeze out one more batch for the last bulkhead I need to tab in for the forward section of the deck.  Then I can lay the deck in place (already cut and glassed on the underside) since I will use resin thickened with 1/4 chopped glass for that part.  Got the other bulkheads tabbed in today before the storms hit.  Been HOT though here in Georgia.  Will post pics tomorrow.

Tip of the day- get some cheap food service plastic gloves, I get them from the dollar store.  100 for a buck.  I use these over my nitrile or latex gloves, never alone of course.  This way I can strip off one or both of the plastic gloves any time I need clean hands and just slip on another pair over the nitrile gloves.  Faster and cheaper and keeps resin, etc off everything else!

[Tim/GA]

Forward sections of the rigging tubes in



Mid-floor section in, the floor section over the fuel tank bay is just layed in right now.  Will cut holes and foam outer sections under the floor later (also the mid bulkhead.



What is this?  What I had thought were pieces of wood 2 ft long tying the transom into the stringers turned out to be chunks of lead!  Each weighs in about 30 pounds or so.  Anyone seen this before?  Those are the chunks in this pic.



Question time.  I had thought I would only have to reskin the inside of the transom but it is looking like I had better replace it now while I am at this rebuild.  I did not cut out the last few feet of stringer or the transom prior to this to keep some strength in the hull.  Now I have the stringers, bulkheads and floor in (all but the center section over the fuel tank) but there is still 5ft between the end of the installed stringers and the transom.



Do I have enough stiffness to tear out the transom now or do I need to lay the stringers closer to the transom before taking it out?

[warthog5]

You should be fine now.

How much glass did you cover the stringer's with? From the pix's, look's like 1 layer of biaxle?

On the rigging tube's. It alway's better to add bigger and or more rigging tube's to a boat.

Why have to fight it? make it easy on yourself to rig and work on latter.

I have a 3in & 4in tube in mine. They are not jambed, but are filled.