Classic AquaSport
Aquasport Model Rebuilds, Mods, Updates and Refreshes => Osprey Style Hull Rebuilds => 200 Rebuilds => Topic started by: Islander on March 18, 2016, 12:06:11 PM
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Hi everyone, I've been lurking for a while - trying to read as much as I can about doing this before I took the plunge. It's been a few years, but I think I'm finally ready to fix this old gal up.
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/IMG_6165.jpg)
I've had this baby for a while. I had some trouble with the motor when I got her. I rebuilt it and had it running for a few years. Last year, there was an electrical problem in the motor that I couldn't figure out so she sat in my yard for a whole season. I've decided that I'm going to try to sell the motor and replace with a newer model (I'll need advice there soon too) but in the meantime, I'm going to finally fix the rest of her up. Here's what I think I need to do but I'll let you guys guide me a little. I'm a bit nervous to do this myself.
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/IMG_6167.jpg)
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/IMG_6169.jpg)
The transom feels solid to me. I have smacked it all over with a rubber mallet and it sounds great. Not sure if that's the best method to do this but, it made sense to me. There are cracks on the cap as you can see in the pic. There are also some spots that were filled by the previous owner. My first question is do you think I need to rebuild the transom or can I let this go if I just fill the cracks and repaint?
Next...the sole. This part has me worried and excited at the same time. I haven't done any repairs at all but I swear it wasn't this bad before last year. It has soft spots but the cracks came from sitting for a whole year. That's totally my fault but I'm here to make it right.
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/IMG_6166.jpg)
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/IMG_6174.jpg)
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/IMG_6173.jpg)
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/IMG_6172.jpg)
As you can see in the pics, there are pretty solid cracks in a few spots. The stringers feel very sturdy though. I have been bouncing around and the soft spots are only in non-stringer areas. I'm guessing that it's better to replace the sole than to fix the cracks, right? I would like to eventually get her back in the water sometime soon but I want to do this correctly too.
I have read a bunch of posts on how this is done and I'm excited to take it on. (Work sucks, so having something to look forward to at night and on the weekends keeps me going.) I am a bit nervous that I will screw something up though...
That's all for now. Looking forward to your wisdom.
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For the transom I would tilt the engine up and put your body weight on it and bounce up and down while watching the transom for flex. If it is solid I would fix the crack and repaint.
Look at this post and in the pics is what my transom looked like and I cut into it to expose what we were seeing.
http://classicaquasport.com/smf/index.php?topic=10101.msg89247#msg89247
If the transom flexes you can use the same link to see how I replaced the transom. ;-)
I would agree on your assessment of the sole. If you're gentle on the demo you can probably reuse the stringers but will probably want to open the tops and dig out the foam and refoam them before putting in a new sole.
I would also plan on re-coring the front hatches, which is very easy.
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Thanks Rick! I just gave that a try and bounced up and down on the engine. The transom didn't move at all. It seems really solid. Hopefully that will be one less thing for me to worry about.
I opened the forward hatch and took a look inside. Stringers seem solid, but I guess I'll find out how solid they are when I get that floor out of there.
I'm going away this week on a job but I'm going to continue to research. I want to start as soon as I get back.
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So I actually did some work this weekend. I know it's not a lot of progress but I'm doing my best to plan this out correctly. I was able to get the tank out and started making cuts to the floor until I realized that I had the wrong blade on my circular saw. What I was able to cut out ended up being completely saturated with water. So I'm afraid that I'm going to have to attack that transom after all. Might as well do it all now, right?
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/IMG_6377.jpg)
The tank sounds like it's aluminum but it doesn't look that way. What is the best way to dispose of it?
I have to go away for work this weekend, so that puts me back another week but I'm really hoping to spend a day or two to get that floor out of there and see how much work I need to do on the stringers.
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(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/IMG_6377.jpg)
The tank sounds like it's aluminum but it doesn't look that way. What is the best way to dispose of it?
Looks aluminum to me.
Recycle it. Beer money. :ScrChin:
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I like the way you think. That's exactly what I'm going to do. Thanks
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I've been nervous about taking the plunge and cutting the deck out but I finally did it! No turning back now.
I was surprised that there isn't more damage. The deck was completely rotten throughout - so I'm glad I did this. For the most part the stringers look good to me. They seem solid and don't appear to have any problems with the exception of a crack at the base of the port stringer. Definitely needs another couple layers of glass on the hull. The transom seemed solid to me but I drilled a hole at the very bottom and found some wet plywood...so it needs to be rebuilt. I'm nervous about doing that. I've been reading so much over the last few months on this site though, so I feel like you guys can help me if I have questions along the way.
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/83713956-9ADA-4B37-9BF1-09A711F718AB.jpg)
Here's a close up of the crack on the port stringer
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/E3447627-22EC-41C5-8B6F-D5E49A74FB42_1.jpg)
Both stringers seem to be well attached to the hull. They don't budge at all. The crack looks like it's just that top layer of glass, but is there a better way to tell if that is a bigger problem?
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Stringers look great. Drill some small holes at the inside base of the stringers near the aft of the boat and see if you get any water out of them. If not, you may have lucked out. If water comes out, now is the time to dig it out. Several ways to do that, once you come to the realization that they're wet...
Then you need to decide what you want for a transom when you are done - full or notched?
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Just drilled some holes in the stringers. The starboard one is bone dry but the port one is damp. Probably a safe bet to do them both now.
I was planning on keeping the transom the same as the original. I have looked at quite a few rebuilds on here with a full transom and I've definitely thought about it - they look great. But since this is my first rebuild, I think it will be better to keep it the same.
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Figure out a way to cut the stringer tops so you don't lose the shape and strength, like maybe cut a 3ft section out of the top, leave a 6" and then cut another 3 ft. Or maybe 2ft cut outs. You only need to cut out enough to allow you in to dig out the foam. When you refill the stringers, after it kicks you can cut the foam across the top and then glass right over the top and the stringers will be like new. If you think you'll be getting a t-top, plan that into where you cut the stringer tops so you can re-inforce those areas.
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Took advantage of the cool weather and spent the weekend grinding down the hull. I probably have another day to go.
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/7F2FB180-80F0-41D5-B999-0D821EE51CE2.jpg)
I also cut out the casting deck. This one made me nervous but I've gone this far...might as well continue.
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/05AD2F61-BBC8-4E41-8BB0-5FA987E523CA.jpg)
I cut a two-foot section in the port stringer near the transom and the foam that I dug out was completely dry. I'm wondering if I should continue? I tested in the middle on the port side and it was dry too. I guess I was mistaken when I drilled the other holes. I bought new foam to replace already, but is it worth it if the stringers are solid and the foam inside is dry?
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If it's dry, don't waste your time - take the foam back (hopefully you bought it locally) and use that money on other materials.
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Ok, grinding is done (for now.) I think I'm ready to start glassing the hull if the temps are good tomorrow. I'm going to leave the foam in place and not touch the stringers. However, there's a crack at the bottom of the port stringer on the inside, mid way up. It looks like it's just the outer layer of glass. My plan is to put a layer of 1708 over the whole hull and over the stringers. Should I reinforce the area with the crack...or will the 1708 that I plan to lay across the entire hull do the trick?
Also, should I lay the 1708 lengthwise (bow to stern) or across the hull? I'm trying to figure out how to lay the glass with the original stringers in place. Is there one method that's better than another?
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I would rough up (extra) around the crack (to smooth glass) and plan to go over it at the same time you're lam'ing the hull/stringers. As are as which way? 1708 comes in 2 weaves - 45 and 90. Seems the more common is the 45. You have to figure out how much cloth you can handle at a time. What are you using for resin? That will dictate the open time you have to work. I ran it front to back but I didn't have stringers in the way. When I set my stringers in place I tabbed them in.
So I think the resin will dictate some of this.
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I'm using epoxy for the hull and the transom, so I think I have more time to work than I would with poly. But I haven't done a lot of fiberglass work in the past, so I should probably be a little cautious.
On the plus side, I tested out my glassing skills today on the casting deck and re-cored the rotten plywood that the hinges for the hatches were screwed into. It didn't turn out too bad and it helped me understand how the epoxy works. It may not be the best job in the world, but I learned a lot from it. It seems solid as a rock too.
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This time of year a slow mix of epoxy will give you a good amount of working time - I've seen it take better than a day to harden. Medium mix is good for smaller mixes on the projects.
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Back at it today. Started to take out the old transom core. Looks are definitely deceiving, I thought just the bottom was rotten, but the whole thing was mush. So glad I decided to do this now.
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/5755369E-3B30-4188-A313-84AB0375FE69.jpg)
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/0A67E0C1-AD76-4ACA-9A5C-27A42F49B183.jpg)
I used an air chisel to get most of it out (thanks for that advice Rick) I don't know how I would have done this without it. I was able to get most of it out today but will probably spend the day tomorrow grinding the rest of the wood out.
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/F1CE076D-9443-4F15-A9CB-E76EF1566B49.jpg)
Now I've got to make a decision about core material. Still leaning toward CoreLite but I'm not 100% sure yet.
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Getting there...i still have another day of grinding, maybe more. At least all of the wood is gone now.
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/6F054677-88F2-4053-9854-607754BA6250.jpg)
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It feels like I'm in the never ending process of grinding still, but I was thinking ahead and had a few questions about painting. I'm using epoxy below the deck and poly above - primarily because I want to gel coat everything. I want to gel coat the outside too...but what happens when I get to the transom?
I'm now going to fully enclose the transom and add a bracket, so I will need to significantly build up my previous outer transom skin to do this. Should I use polyurethane resin to build up the outer skin? Then switch to epoxy for everything else - like securing the core to the new skin?
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What kinds of a bracket are you thinking? A Porta-bracket? Or a flotation type bracket?
Keep in mind you can bond epoxy on top of poly but not the other way around.
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I have a question that might be dumb but I don't want to go too far - or not far enough.
Here's a look at the port side corner of my transom. The top part was ripped off when I was removing the rotten core. Do I need to grind down to that layer of glass or is that too far?
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/CCB4E3F4-68FC-4DE6-B615-B2D31F15451C.jpg)
Here's the same corner, toward the bottom. You can see the cracking in what appears to be thickened resin. I'm thinking that I need to grind all of that off. Is that correct?
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/1ACCC815-8DBC-44CC-A879-D1C5554E549D.jpg)
Here's a wider shot to make it easier to put it into perspective. I was dry fitting the dam to see if I had enough melamine.
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/2F961D79-158C-4B26-ABB4-C810565BEA8F.jpg)
What kinds of a bracket are you thinking? A Porta-bracket? Or a flotation type bracket?
Keep in mind you can bond epoxy on top of poly but not the other way around.
I'm going to put a flotation bracket on there.
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Grind everything smooth - thickened resin has to go too. Are you going full transom?
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Great, thanks. I didn't want to keep grinding past the point of no return but that makes sense.
Yes I'm going to a full transom now.
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Alright...finally some progress!
(http://img.photobucket.com/albums/v394/jxdemaio/Aquasport%20Osprey%20200/0D4FED43-BA84-4812-A042-D910A9E590DE.jpg)
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Looking good - that's a big leap forward!
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Well, I’ve hit a bit of a snag with this rebuild. My homeowners association isn’t going to allow me to keep the boat on the side of the house and it’s just a little too big to fit in the garage. Does anyone know of any covered storage places or garages in the Longwood/Lake Mary/Altamonte Springs/Sanford area where I can continue this?
Otherwise, I guess I’m going to have to sell it. I’m tired of the battle here.
Thanks,
John
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How's it going man? Do you still have the project?