Classic AquaSport
Aquasport Model Rebuilds, Mods, Updates and Refreshes => Osprey Style Hull Rebuilds => 200 Rebuilds => Topic started by: Tampa Bay Mike on August 09, 2020, 08:39:44 PM
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Well, I finally talked my buddy Nate into giving his 200 Osprey some love. If you've ever been around the 59th St boat ramp in Bradenton, chances are you have seen ol Caught Looking before. We have caught more fish out of this boat then I could ever count. In fact, my avatar picture was taken while pulling a tarpon up over the side of her. But with a soft floor and a flexing transom it is finally time. Nate admittedly is not much of a blogger so I told him I would get a rebuild thread going for him.
The plan is to keep is relatively simple. Strip it down, replace the transom with coosa, new nidacore floor panels, re-core the front hatches and the cap where needed, new console, rewire everything, and repaint. Oh, and the original console and tower are for sale if anyone is interested. Possibly the livewell too, but he hasn't completely decided on that yet.
(https://classicaquasport.com/gallery/data/500/20200725_124656.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20592&title=20200725-124656&cat=500)
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Some more pics of the damage so far.
Un-rigging everything. Livewell gone
(https://classicaquasport.com/gallery/data/500/20200725_145629.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20593&title=20200725-145629&cat=500)
Tower and console next. Rats nest anyone?
(https://classicaquasport.com/gallery/data/500/20200725_150833.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20594&title=20200725-150833&cat=500)
Barely had to unscrew the fuel tank hatch. It was so rotten I could just pry it up.
(https://classicaquasport.com/gallery/data/500/20200725_154950.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20595&title=20200725-154950&cat=500)
The tank was just sitting in there with some foam around it...
(https://classicaquasport.com/gallery/data/500/20200725_155552.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20596&title=20200725-155552&cat=500)
Floor cut out.
(https://classicaquasport.com/gallery/data/500/20200805_160810.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20597&title=20200805-160810&cat=500)
I think the foam is wet!
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_4_.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20606&title=imagejpeg-0-4&cat=500)
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_5_.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20607&title=imagejpeg-0-5&cat=500)
All cleaned out.
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_1_.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20604&title=imagejpeg-0-1&cat=500)
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Got started on the transom next. Someone had raised it 5" at one point in the past and I am betting that is the only (semi) solid wood left in this thing.
(https://classicaquasport.com/gallery/data/500/20200805_160758.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20609&title=20200805-160758&cat=500)
We made some openings in the cap to get access to tab the new transom in.
(https://classicaquasport.com/gallery/data/500/20200805_160917.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20610&title=20200805-160917&cat=500)
These liners are a pain. We kept the cutouts for now in case we decide to tab it back in, but we may end up coming up with something different when it comes time to put it back together.
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So that's where she's at now. Next up is breaking the skill saw back out to finish off the transom and then the back ends of the stringers will come off so we can start prepping for the coosa.
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The stringers look to be solid.
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The stringers look to be solid.
Overall they look okay. There is one small crack on the starboard side where the fuel tank coffin was screwed to it, but that should be an easy fix.
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Been chipping away at the inside of the transom little by little this week. Anyone have any miracle tips besides the tried and true skilsaw checkerboard and chip method?
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Tried and true works. An oscillating multitool is good for tough spots.
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The oscillating tool sounds like a good idea to try. Thanks
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Air chisel after the circ saw.
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Nice. I have flashbacks from a few months ago. Enjoy and wear plenty of talcom powder or tyvex suits 🤣.
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Nice. I have flashbacks from a few months ago. Enjoy and wear plenty of talcom powder or tyvex suits 🤣.
Haha, yup, me too. Luckily for me he's doing most of the dirty work.
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Nice work.... following this rebuild.
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Hey. Cool your doing another one and this time for a friend!
Great lookin' boat!
What price does he want for the tower? It should fit my original console too
And can you find out if he thinks the 115 has plenty of power for the boat? Top end? Average MPGs?
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Tower is availiable $600
The 115 has plenty of power for my needs. Not a speed demon but enough to help me cut through the chop on a bumpy day. I dont know the actual speed or MPG's I was getting. I would estimate in the 30's for speed. And for a full 8 to 10 hour day of fishing around 6 gallons of fuel. If your interested in that tower send a PM.
Thankyou,
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Hey, look who emerged from the land of fiberglass dust!
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Hey. Cool your doing another one and this time for a friend!
Great lookin' boat!
What price does he want for the tower? It should fit my original console too
And can you find out if he thinks the 115 has plenty of power for the boat? Top end? Average MPGs?
Luckily I get to play more of a consulting role on this one. At least until the heavy grinding is done. ;-) I'm sure I'll be a lot more involved once we get to the fun parts.
It's actually a nice tower. Nothing fancy but it's sturdy, fits great over the stock console and there's plenty of room for two people.
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Here are a few pics from the transom demo. The part where it was raised 5" was glassed in pretty well and is taking the longest to remove. Everything below that was pretty wet and isn't putting up much of a fight.
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_7_.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20658&title=imagejpeg-0-7&cat=500)
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_8_.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20659&title=imagejpeg-0-8&cat=500)
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I’m running a 2003 “YAMAMERC” 115 on a 1996 Osprey 200. Wife, 3 kids, 30 gallons of fuel, Bimini top and a bow dodger. We top out at 38mph. It’s plenty of power on these hulls.
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I’m running a 2003 “YAMAMERC” 115 on a 1996 Osprey 200. Wife, 3 kids, 30 gallons of fuel, Bimini top and a bow dodger. We top out at 38mph. It’s plenty of power on these hulls.
A 115 has always worked fine on this boat too. Gets up on plane just fine and runs all day on 10 gal of gas.
So I've been getting some progress pics from Nate. He's been grinding away at the transom a little each day.
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_10_.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20806&title=imagejpeg-0-10&cat=500)
Think it's finally ready to go
(https://classicaquasport.com/gallery/data/500/PART_1598477659198_Resized_20200826_173128_8245.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=20805&title=part-1598477659198-resized-20200826-173128-8245&cat=500)
Been stocking up on supplies to put it back together too. We should be ready to get the new transom in soon.
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Nate and Mike I do believe you just answered one of my questions about mileage. I just started on a 200 rebuild and the tank has been replaced with about a 30-35 gallon one. It's looking good! Anxious to see the transom and floor go in.
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Mike its good to see you getting your hands dirty on a 200 😆. I loathe grinding and sanding. No matter how much talcum powder I put on i itch every single night when I lay down in bed... And forget the tyvex suits.... i seen to rip them as fast as I can get them on. Maybe I should shop at the big boy tyvex store. Haha. Solid work. Keep it up!!
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Mike its good to see you getting your hands dirty on a 200 😆.
This is the best way to rebuild a boat! 😁
Actually I am still getting a little itchy. While he's been prepping the transom I've been working on a leaning post livewell for him. I'll post a few pics of it soon. Its almost ready for paint.
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Here are some pics of the leaning post so far. The well should be around 35-40 gallons.
(https://classicaquasport.com/gallery/data/500/20200815_155805.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20813&title=20200815-155805&cat=500)
Yes, I started this in my bedroom because it was so hot out that day 😆
I clamped some airex type stuff together to get the initial shape
(https://classicaquasport.com/gallery/data/500/20200817_193138.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20814&title=20200817-193138&cat=500)
Mold loaded up
(https://classicaquasport.com/gallery/data/500/20200819_190213.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20815&title=20200819-190213&cat=500)
Layer or two of ounce and a half, 1708, coremat, and 1708. A sold quarter inch thick on the sides and almost a half inch in the corners where it overlaps. Solid
(https://classicaquasport.com/gallery/data/500/20200819_195216.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20816&title=20200819-195216&cat=500)
Mold came apart clean, but I did have a few dry spots in the corners. Seemed like the clay I used to make the fillets pulled a little of the resin out? Oh well, nothing that couldn't be easily fixed.
(https://classicaquasport.com/gallery/data/500/20200820_165121.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20817&title=20200820-165121&cat=500)
Trimmed and faired. I still need to tweak the lid a little bit that's where we stand as of now.
(https://classicaquasport.com/gallery/data/500/20200829_170042.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20818&title=20200829-170042&cat=500)
(https://classicaquasport.com/gallery/data/500/20200829_170049.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20819&title=20200829-170049&cat=500)
Now it's just waiting on someone to finish grinding 😉
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:great02:
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Looks good Mike.
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Aww man my rebuild just got delayed again, gonna have to make one of those! Your pics make it look easy. Nice work!
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Great work mike! I like the live well build. Thanks for sharing. :)
Ulysses
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Looks awesome Mike! I picked up some plywood to start mine today. I had never really seen how they were made with molds. My plan was to build it out of 1/2" ply and glass it. Your way would definitely be lighter. I already have my materials but suppose I could use a pva or alternative method to seal the wood. So many ideas. Keep up the great work.
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Thanks guys.
Copacetic, I was able to fit the entire pattern on one sheet of melamine. If you decide to give it a shot it may be easier to buy a sheet for $25 instead of trying to seal up the plywood.
I also got curious about the weight so I stuck it on the scale and it's 54 pounds.
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The leaning post/livewell is impressive. Well done.
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I really wasn't loving the fiberglass lid so I picked up a sheet of 1/2" acrylic and made a new one last night. I'm much happier with this one.
(https://classicaquasport.com/gallery/data/500/20200901_193930.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20834&title=20200901-193930&cat=500)
(https://classicaquasport.com/gallery/data/500/20200901_193925.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20833&title=20200901-193925&cat=500)
Had some Gemlux friction hinges and a latch left over from my build that worked great.
(https://classicaquasport.com/gallery/data/500/20200901_193945.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20835&title=20200901-193945&cat=500)
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Better choice. How will the inside of the tank be finished?
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Better choice. How will the inside of the tank be finished?
It will probably get a little fairing and then a roll of light blue gelcoat. I'm not going for a perfect finish inside. It would have been easier to do before I put it together but I ran low on fairing compound and didn't bother buying another small tub now since we will end up getting more later to finish everything else
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Yeah I looked at that small opening and saw major chiropractic work coming my way ;-)
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Diggin the acrylic Mike it definitely looks better than the solid lid. I will post a few pics later of where i started on mine. Decided to just use 1/2 ply since i had it and at least get a mock up done so i can seen how it will look. Been workin late and yesterday was the first day I've had time for anything.
Just curious how are you going to run your plumbing for it? Raw water or just an aerator?
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Yes, I'm much happier with the acrylic as well.
We're going raw water with the plumbing. Once we get the floor panels glassed up and dry fit we will be able to place it and mark everything up for the pipes. I left a half inch or so under the bottom of the well so I can recess the drain once we figure out where it'll go.
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Transom is ready for glass. Got the coosa, five sheets of nidacore, a roll of 1708 and some mat the other day. Should be ready to start putting her back together soon.
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_13_.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20843&title=imagejpeg-0-13&cat=500)
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_12_.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20842&title=imagejpeg-0-12&cat=500)
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_11_.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=20841&title=imagejpeg-0-11&cat=500)
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The transom is in! We actually started it a few weeks ago but just got around to adding the last few layers of glass this morning. We started by adding a layer of 1 1/2 oz mat to the hull to fill in some imperfections and give us a good bonding surface for the new glass. Then six layers of 1708 were added to the notched area that was raised by the previous owner to bring it level with the rest. That was followed by three layers of 1708 over the whole transom with 4, 8 and 12 inch overlaps on the sides and bottom. The coosa was bolted in next with a bunch of bonding putty before the first layers fully dried to try and get the best bond. We used two 3/4 inch pieces laminated together with a layer of ounce and a half between them. Then today we filled the edges with some structural filler and added the inside three layers again with 4, 8 and 12 inch overlaps.
(https://classicaquasport.com/gallery/data/500/20201003_143917.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=21049&title=20201003-143917&cat=500)
A few blocks and some wood screws gave an impressive bond.
(https://classicaquasport.com/gallery/data/500/20201003_164733.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=21053&title=20201003-164733&cat=500)
(https://classicaquasport.com/gallery/data/500/20201003_180529.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=21050&title=20201003-180529&cat=500)
Edges sealed and bolt holes filled.
(https://classicaquasport.com/gallery/data/500/20201017_091920.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=21051&title=20201017-091920&cat=500)
Final layers.
(https://classicaquasport.com/gallery/data/500/20201017_104714.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=21052&title=20201017-104714&cat=500)
I've got some inch and a half coosa leftover from my build that we are going to use for some knees and then we'll get the stringers back together.
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That transom looks very stout. The first pic had me thinking that the inner core was still there - optical allusion ;-)
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That transom looks very stout. The first pic had me thinking that the inner core was still there - optical allusion ;-)
Haha, after as much time as Nate spent grinding there better not be any wood left!
When the transom was raised from 20 to 25 inches it appears to have been mainly cosmetic. The glass was pretty thin there but there was a big lip leftover where the factory transom ended.
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Looks good, What about running knees forward enough to tab a crossmember across them to both stringers and lay deck on it or running knees to essentially a bulkhead and lay deck on. I’m considering this or should the deck be independent of the transom ?
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Not completely sure how the back is going to get finished yet. We were thinking about maybe just enclosing the space between the knees to hide the rigging and leaving the rest open. A top deck all the way across could be cool to use for transom seating and such but then we would lose a little standing room. Since it's only a 20' boat he wants to maximize the space inside.
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The transom is finally done. ✔ Last week Nate got the top of the transom rounded over with the router and added a strip of 1708 to seal it up and a sacrificial layer of mat for fairing. I went over this morning and helped get the stringers glued down and tabbed back in.
(https://classicaquasport.com/gallery/data/500/20201121_120642.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=21280&title=20201121-120642&cat=500)
Between the factory glass, the blue structural putty, the gray coosa, the white bonding putty, the new glass and a little bit of red MEK-P that we used on the last layer of tabbing, it looks like a hot mess but man it feels solid.
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Looking good - looks like the design has changed i.e., no knees?
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Yeah we decided to forego the knees. Our thought was that it's already 100x stronger than the rotted wood we took out, and after we glass the rear cap back on and tab the floor into it we should be good. If we had gone with a full transom with a bracket I would have, but this is staying at 25" and will only have a 115 so it should be plenty strong
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Sounds like a plan :nSalute:
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Had to do a little surgery on the starboard stringer before getting too much further. Good news is the foam is dry. Bad news was the tank was not secured properly and it was rubbing on the hull which caused the stringer to delaminate some.
Started out by cleaning it up with the grinder and chasing the crack as far back as needed.
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_14_.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=21352&title=imagejpeg-0-14&cat=500)
Then went back and added a few layers of 1700 to bring the hull bottom back up flush with the rest.
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_15_.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=21353&title=imagejpeg-0-15&cat=500)
Finally the remaining gap was filled with bonding putty and the entire stringer was glassed back down with three layers of 1708 with 4, 6 and 8 inch overlaps.
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_16_.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=21354&title=imagejpeg-0-16&cat=500)
We were trying not to walk around in the hull too much to prevent it from separating more so now that it is secure we can focus on the stringer tops and then start on the floor.
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Yeah, the tabbing they used was just woven roving. The 90 degree orientation of fibers after means little strength where it is needed most. Biax 1708 or similar will result in a much stronger tab. Great news that the foam is dry. That will save money and time.
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Yes, saving time and money is always good! Now the center stringer can be addressed before prepping for the tank to go back down.
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Nothing really photo worthy but we're still picking away. Got the stringers fixed up and raised using the same method as my boat. Added some more glass to the hull bottom since there was so much sanding and started templating up the bulkheads. Also got a new fuel tank and finalized the layout for everything. Should be moving quicker here soon.
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Hey everyone its been a little while. I am working with Nidacore I glassed the top and bottom of panel and was wondering what techniques do you use in filling the edges of the nidacore? Feel free to explain the concept and reason why its important. Im sure its obvious but I just need a solid answer.
Thanks
Thanks
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What are you using the Nidacore for?
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I used a similar composite for my decking/sole and had to figure out how to work with it. Here is the portion of my rebuild where I was working the deck.
https://classicaquasport.com/smf/index.php?topic=10101.msg113660#msg113660
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Hey Rick. We're using it for the sole but here's the current dilemma. For some reason the aft six foot or so of the stringers are an inch lower than the front. There's a dip right behind the old wiring trough. We used blocks of pvc to raise them up but need to level out the back. We were thinking a strip of 3/4" nidacore with two layers of glass on each side and a little putty should do the trick, but that got us thinking about the edges. Is it worth filling the edges of something that won't ever see the light of day again? In the grand scheme of things it's not a lot of effort or money so we will probably just do it, but we're curious what the consensus here is.
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_14_1.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=21750&title=imagejpeg-0-14-1&cat=500)
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The core is plastic so it should be fine BUT I am not sure if it sat in water what would happen. I think I would put a small square of it in a bucket of water and see if it affects the glass any. Maybe weigh it down and leave it for a week?
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Still plucking away at it. We got the stringer dilemma figured out with a coosa board shim. Not sure if all these 80s model 200s had the same stringer setup, or if this was just a Friday boat but man it was off. My 22-2 was straight all the way back. Oh well, it's straight now and ready for the floor.
(https://classicaquasport.com/gallery/data/500/imagejpeg_0_14_2.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=21885&title=imagejpeg-0-14-2&cat=500)
We also decided on a big floor hatch for the front and one for each side so some bulkheads were in order. Went ahead a made a new tank coffin while we were at it to keep it off the hull bottom. It took a while given the limited time he has to work on it but it will be nice when it's done.
(https://classicaquasport.com/gallery/data/500/20210610_155904.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=21884&title=20210610-155904&cat=500)
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Next big checkmark done! We finally got a free weekend day off together and got the floor down. It's nice to finally have it coming together. I'm going to keep on Nate to get this thing done and hopefully have it back on the water this summer.
Tank secured, hoses double clamped and double checked, storage boxes and bilge gelcoated and ready to go.
(https://classicaquasport.com/gallery/data/500/20220108_150856.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22296&title=20220108-150856&cat=500)
Floor down. We used about a gallon and a half of bonding putty from FGCI to make sure it was stuck good and then went around the edges with some fiber reinforced filler to help lock it all in place. Now that it is dried Nate can add some tabbing and fair out a few small spots on the seams
(https://classicaquasport.com/gallery/data/500/20220108_161701.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22297&title=20220108-161701&cat=500)
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Nice progress guys :thumleft:
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Nice going! Looks like it’ll be easy fairing. Sure hope you wrote down some good measurements where all that subfloor stuff and hatches comes thru! ;-)
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Thanks. We did take a lot of measurements and even marked the hullsides where the bulkheads are. The hatches are on order so hopefully they should be in soon.
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Hey all. I don't have any updated pics right now but the project is still moving along. I stopped by Nate's house this morning to check it out. The floor is glassed down and faired. The floor hatches are all cut out and ready to install. The leaning post/livewell is glassed down and ready for primer, and he glassed some coosa down in preparation to install the console. Going with paint since it was painted previously. All that's left is a little cosmetic work on the gunnel cap, final fairing, primer and paint, electrical and rigging. I'm pushing him to get it done before the end of the summer. Be a lot quicker if he could pick a paint color lol.