Classic AquaSport
Aquasport Model Rebuilds, Mods, Updates and Refreshes => Osprey Style Hull Rebuilds => 240 Rebuilds => Topic started by: Ulysses485 on March 23, 2022, 04:22:36 PM
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Unexpectedly, my "240 Family boat" project took a turn on me. Hopefully for the better on the back end of the project (Gelcoat finish). However, I am going to have to get the circular saw, multi-tool, Sawzall, chisel, etc. back out. Going from a cabin style hull (Seahunter) to CC project would have been challenging (due to stringer layout) for me with how I wanted it and keeping the raised cap. Also, the opportunity was too easy to pass up. The inside is complete filth and someone laid textured gelcoat everywhere that is peeling (from what looks to have been really poor prep) but its all coming out anyhow (undecided on if I want to keep or rebuild the casting deck). The center console it came with is HUGE and although I do like the helm layout, it will likely get replaced unless i can cut it down and make it a reasonable size. The hullside looks to be original gelcoat and a layer of thin gelcoat that was improperly applied that is proving easy to sand down. The 200hp 2.4L 20'' Merc on the back was sold last weekend.
So here it is..an Aquasport 240 Original Center Console outboard model. It is neat to finally see the rare specimen that is the Aquasport 240cc outboard model which I have only really seen in brochures.
The day after I got it....
(https://classicaquasport.com/gallery/data/946/IMG_11661.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22570&title=img-11661&cat=946)
Some of the listing photos:
(https://classicaquasport.com/gallery/data/946/IMG_1140.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22573&title=img-1140&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_1146.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22574&title=img-1146&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_1148.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22568&title=img-1148&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_1150.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22569&title=img-1150&cat=946)
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Made some Demo progress.. nothing all that exciting but its progress. Most of this demo will likely happen at night when i have time in bad lighting so I apologize for the poor quality photos.
Removing the Console (its HUGE, and may sell it for something narrower if i see too much work out of a modification):
(https://classicaquasport.com/gallery/data/946/43A9F0BF-46CE-485F-A225-BC3BAC2E8C1C.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22611&title=43a9f0bf-46ce-485f-a225-bc3bac2e8c1c&cat=946)
(https://classicaquasport.com/gallery/data/946/7D332A85-BBE1-4AC8-B868-4D879B6F427B.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22603&title=7d332a85-bbe1-4ac8-b868-4d879b6f427b&cat=946)
Fuel Tank Removal:
(https://classicaquasport.com/gallery/data/946/8DB6D4F9-C7C1-441D-B20A-1CBFA80D4290.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22613&title=8db6d4f9-c7c1-441d-b20a-1cbfa80d4290&cat=946)
There was a bed of foam that the fuel tank was laying in. Completely saturated in water.
(https://classicaquasport.com/gallery/data/946/3AD07E55-5741-4843-A7EB-E57E89A1F7E0.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22610&title=3ad07e55-5741-4843-a7eb-e57e89a1f7e0&cat=946)
After foam was removed:
(https://classicaquasport.com/gallery/data/946/6B8BB858-999A-4E10-A31E-5AA3462E695F.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22612&title=6b8bb858-999a-4e10-a31e-5aa3462e695f&cat=946)
Almost felt like i was gardening. Never thought i would need a shovel in a boat.
(https://classicaquasport.com/gallery/data/946/6889954B-DF65-4396-902E-4733A4372D2A.png) (https://classicaquasport.com/gallery/showphoto.php?photo=22602&title=6889954b-df65-4396-902e-4733a4372d2a&cat=946)
Debris removed:
(https://classicaquasport.com/gallery/data/946/3A087538-3111-4A69-A450-097AD0BD08C1.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22609&title=3a087538-3111-4a69-a450-097ad0bd08c1&cat=946)
Got after the bottom paint using attachment for pressure washer I got on amazon and it worked better than expected. However, it has proven to be pretty rough with the sakcrete sand i got from lowes. The play sand was wet so i opted for this one. Fairing the bottom is in my future. :16:
(https://classicaquasport.com/gallery/data/946/47E3D40E-1FB4-4D43-A21F-BCE259B0AC94.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22601&title=47e3d40e-1fb4-4d43-a21f-bce259b0ac94&cat=946)
THERE IS EPOXY BARRIER COATING THAT WONT COME OFF WITHOUT SANDING:
(https://classicaquasport.com/gallery/data/500/3CFA619E-B4D2-48B4-8771-CAF12C3F4F72.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22628&title=3cfa619e-b4d2-48b4-8771-caf12c3f4f72&cat=500)
AFTER SANDING:
(https://classicaquasport.com/gallery/data/500/52626058-839B-4DFC-8AC8-29B4D6466AF5.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22627&title=52626058-839b-4dfc-8ac8-29b4d6466af5&cat=500)
(https://classicaquasport.com/gallery/data/500/9742CA11-5C83-46D0-8C8D-C5B25906E139.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22629&title=9742ca11-5c83-46d0-8c8d-c5b25906e139&cat=500)
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Diving right in. Nice! That console is huge but it looks nice. I'm looking for a similar shape for mine but need it to fit my tower. What attachment did you use to remove the bottom paint? I'll probably be removing mine down the road and pressure washing sounds better than sanding it all.
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Diving right in. Nice! That console is huge but it looks nice. I'm looking for a similar shape for mine but need it to fit my tower. What attachment did you use to remove the bottom paint? I'll probably be removing mine down the road and pressure washing sounds better than sanding it all.
I make progress now with a better understanding of what I am doing. Time is running out...The boys are growing and need to get them on the water....lol! It will still be a "slow build" with limited time but my best progress is made with a lot of little projects that coincide with the proper time intervals and noise ordinances. Large layups will eventually happen on weekend summer nights.
The console has nice layout and could make it narrow but its 48'' long. Glass inside is raw and looks to be biaxial but thin and uncored.
The sandless blaster attachment is cheap on Amazon. It wont remove the epoxy barrier but I'd much rather hold the pressure washer gun then put my shoulder behind a DA or polisher sander AND wear the nasty green/blue bottom paint. I see myself going through A LOT of sand though. I went through just under 3 bags to remove the water line on one side. I might throw some tarps down to see if I can catch some of it but then it would have to be dried back out.
Link to Blaster attachment:
https://www.amazon.com/Tool-Daily-Sandblasting-Sandblaster-Attachment/dp/B08DNPJDSG/ref=sr_1_4?crid=30ZTLN43ZMALJ&keywords=dustless%2Bblaster&qid=1648820463&s=hi&sprefix=dustless%2Bblaster%2Ctools%2C62&sr=1-4&th=1
(https://classicaquasport.com/gallery/data/946/Sandless_Blaster_Attachment.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22630&title=sandless-blaster-attachment&cat=946)
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Really cool boat. Can't wait to see the finished product.
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Chipping away slowly....
After about approximately 10hrs, 13 sand bags, multiple 80 Grit DA sand pads, I didn't get nearly as far as I wanted (first picture) so I brought out the trusty Dewalt Rotary Polisher/Sander and it removed more material in 1hour (second Picture)….
(https://classicaquasport.com/gallery/data/946/EBF38EB4-615E-4239-99D4-7FA0D7436B69.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22699&title=ebf38eb4-615e-4239-99d4-7fa0d7436b69&cat=946)
(https://classicaquasport.com/gallery/data/946/5DC25AF2-6679-413A-A67E-BF32664FB6EA.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22697&title=5dc25af2-6679-413a-a67e-bf32664fb6ea&cat=946)
Still have to get to the Starboard side...:/ I might be trying out the Citristrip paint remover.
(https://classicaquasport.com/gallery/data/946/FA04F974-73DD-4D69-8E5E-91741D07778B.png) (https://classicaquasport.com/gallery/showphoto.php?photo=22700&title=fa04f974-73dd-4d69-8e5e-91741d07778b&cat=946)
Cleaned up the console to "see it better" lol... I might be able to make it work with modifications. I like the details and height so I would narrow it down a little and maybe shorten the depth as it is about 48'' long (w/o flanges).
(https://classicaquasport.com/gallery/data/946/CA03050C-0AF7-4C0A-9C33-77853DCB6F08.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22698&title=ca03050c-0af7-4c0a-9c33-77853dcb6f08&cat=946)
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Now that some cooler weather is before me (it was a hot and wet summer….aaaannd I got a 28ft Hull that will suit my offshore itch) I got a few days to finish some more demo on this 240 project. I gave up on removing bottom paint for now so I moved to a more productive feeling part of the rebuild, hehe.
Got the cap pulled to get the casting deck out and finish the rest of the interior demo. I ran across a wooden gantry that has worked out great. I wanted to build a shop but pricing for them got out of hand so hopefully that will come soon now that prices are starting to discount.
(https://classicaquasport.com/gallery/data/946/IMG_27232.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22943&title=img-27232&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_27221.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22942&title=img-27221&cat=946)
Main deck cutout, casting deck removed, and transom splash/storage/bait well removed.
(https://classicaquasport.com/gallery/data/946/IMG_2728.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22945&title=img-2728&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_2730.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22946&title=img-2730&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_27563.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22947&title=img-27563&cat=946)
It was impressive to see really how big the casting deck is at 7ft deep. A good portion hidden by the front part of the bow.
(https://classicaquasport.com/gallery/data/946/IMG_27752.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22948&title=img-27752&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_27802.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22949&title=img-27802&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_27852.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22950&title=img-27852&cat=946)
Pressure washed, cap reinstalled, chine/keel blocked/leveled, and in place for the stringers to be gutted of the old foam. The plan is to cut sections out of the top so glass work can be done inside the stringers but the structure is kept for extra precaution.
(https://classicaquasport.com/gallery/data/946/IMG_2800.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22951&title=img-2800&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_2801.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=22952&title=img-2801&cat=946)
I plan to keep the glass layup the same as below from my seahunter project (I might extend the hullside coring to the chine below deck but torn between keeping the existing liner and extending it further back or fairing the inner hull side). I did find out that the CC model has a different stringer grid structure that is also about 2'' taller than a 72' Seahunter)
(https://classicaquasport.com/gallery/data/906/2A34707C-EAF4-406F-87CF-90BE2DBD1D70.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22355&title=2a34707c-eaf4-406f-87cf-90be2dbd1d70&cat=906)
(https://classicaquasport.com/gallery/data/946/Stringer_REbuild.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=22953&title=stringer-rebuild&cat=946)
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Looks like you have some good plans (and a huge fleet)
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Made a little progress over Thanksgiving break and extra days off during Christmas/New Year’s:
- Removed all the foam from the stringers (12 kitchen bags worth).
- Pressure washed all the debris and excess foam bits from inside the stringers.
- Removed the plywood backer from the inboard side of both stringers (this was news to me about this being here but I got it out eventually through the cutout that I made).
- Removed the waterline bottom paint so I am left with about 33% and then I can start filling voids, making repairs, and I’ll be ready for gelcoat.
- Removed a bunch of delaminated glass inside the stringer that was repaired and from the bulkheads that were partially tabbed back in during the process of removing the fuel tank liner.
Plywood backer inside stringer:
(https://classicaquasport.com/gallery/data/946/IMG_30732.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=23050&title=img-30732&cat=946)
An Old repair from a hull bottom gash that led someone to do a poor job or repairing the hull and cutting up the bulkheads etc.
(https://classicaquasport.com/gallery/data/946/IMG_30761.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=23051&title=img-30761&cat=946)
Foam removed (this was 6 bags already filled):
(https://classicaquasport.com/gallery/data/946/IMG_3087.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=23052&title=img-3087&cat=946)
Strange but there seemed to be two different types of foam filling. Not sure what density but the one at the bottom seemed to be like a 2lb or less vs that on top which was more dense (almost as if they were trying to save costs or hide it from some kind of QC inspection (not sure if that is a thing in boat building to meet minimum coast guard regulations of the 2lb regulation):
(https://classicaquasport.com/gallery/data/946/IMG_30931.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=23053&title=img-30931&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_31413.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=23054&title=img-31413&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_31422.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=23055&title=img-31422&cat=946)
Love those smooth radius lines of this hull:
(https://classicaquasport.com/gallery/data/946/IMG_3151.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=23057&title=img-3151&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_3377.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=23059&title=img-3377&cat=946)
Clean up of all foam and ready for a grinder/sander to prepare for rebuild of bulkheads, stringer tabbing, etc.
(https://classicaquasport.com/gallery/data/946/IMG_31481.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=23056&title=img-31481&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_3320.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=23058&title=img-3320&cat=946)
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Looks like you have some good plans (and a huge fleet)
Big plans indeed. However, with a growing fleet, resources are going to be spread thin but I think sanity or reality might come my way to part with one or two of them in the coming years (namely the 81' 222). Not ready for that yet, lol Its when the big dollars are spent that I start thinking long and hard, because labor is free, RIGGHHHT! LOL
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As to the foam, my guess would be that they ran short that day and completed the process with what was on hand or could find quickly. That also applied to composite transom casting where if short of composite, plywood was substituted on the assembly line...
Or so we were told in the past. :ScrChin:
Coming along nicely. :thumright:
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I'm happy to see this is still an active build, because I am considering buying a 1977 240 cc myself! Any ideas on what you will do with the transom?
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As to the foam, my guess would be that they ran short that day and completed the process with what was on hand or could find quickly. That also applied to composite transom casting where if short of composite, plywood was substituted on the assembly line...
Or so we were told in the past. :ScrChin:
Coming along nicely. :thumright:
I thought the same as there were other items tossed in the batter (2x blocking, fiberglass cutouts, etc.) haha. However, it seemed that all the lower density foam was toward the bottom, as if was being hidden from someone. Either way, it was interesting to find it this way.
I'm happy to see this is still an active build, because I am considering buying a 1977 240 cc myself! Any ideas on what you will do with the transom?
I'm guessing your looking at picking the one up with the red bottom paint? That a solid project. Its a shame how they have gone about it thus far. Yeah I pick at this 240 when the time is available. The transom will get molded similar to how the bottom section is and it will rise to the top corners. I thought about cutting off the back end but I don't want to loose the shape of the hull nor do i feel its worth the extra effort to me. It also keeps its originality doing so. It will likely create some hurdles with trim tabs and swim ladder etc. Time will tell as I plan to complete the inside stringers etc. first.
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Yes, that red bottom paint is one of the options out there. I'm also considering a Seahunter that will need to be completely taken apart & rebuilt also. I just found out how small the cuddy cabin is up front though, so I may just sit back for a little while longer to see what pops up. Good luck with yours! I'll be following.
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After many days of prying delaminated tabbing by hand (thank god those days are behind me) and sanding/grinding, I have been able to lay almost the entire hull bottom (even inside the stringers) with at least an extra layer of 3610 0/90 Degree glass so I have met my goal. I also tabbed the inside of the stringers with a layer of tabbing so this thing is on its way to being a military combat vessel. :72: The fuel tank subfloor project was completed and this plastic honeycomb materials has proved to be very stiff and strong when laminated. As of this past Wednesday I have gone through 15 gallons of Polyester resin on structural work and the fuel tank subfloor. I have two (2) more bucket pails of resin which should get me through the structural components, foam fill and cap the stringers to get ready for fuel tank and deck. I am planning to build the deck on a mold table to help with fairing and ease of use with the 1'' plascore honeycomb coring material I have.
Note: A LOT of woven roving tabbing for the stringers were delaminated or just poorly adhered. It seems prep was bad or the hull got dirty because of lack of storage from what I saw. We may never know as history and the men and women who laid these beautiful classics up are likely retired or no longer with us.
First layer underneath both stringers and tabbing for rear section of stringers.
(https://classicaquasport.com/gallery/data/946/IMG_7112.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23776&title=img-7112&cat=946)
Transom gutted after rear stringer section was more structurally connected to hull:
(https://classicaquasport.com/gallery/data/946/IMG_7127.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23777&title=img-7127&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7226.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23778&title=img-7226&cat=946)
Mockup of the transom melamine "mold":
(https://classicaquasport.com/gallery/data/946/IMG_7243.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23779&title=img-7243&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_72441.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23788&title=img-72441&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7245.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23789&title=img-7245&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7247.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23790&title=img-7247&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7250.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23792&title=img-7250&cat=946)
Casting deck Prep. Removed all the poorly tabbed storage boxes to respray with gelcoat and glass/insulate back on casting deck:
(https://classicaquasport.com/gallery/data/946/IMG_7249.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23791&title=img-7249&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7251.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23793&title=img-7251&cat=946)
Cut the sections of the console where many holes were to lay back flat glass in one shot against some melamine mold:
(https://classicaquasport.com/gallery/data/946/IMG_7259.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23795&title=img-7259&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7253.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23794&title=img-7253&cat=946)
More hull bottom glass build up progress and beneath stringers:
(https://classicaquasport.com/gallery/data/946/IMG_7350.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23797&title=img-7350&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7351.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23798&title=img-7351&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7387.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23802&title=img-7387&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7388.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23803&title=img-7388&cat=946)
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The hull does look to be ready for battle!! I wondered how you were going to reglass the weird transom those 240s have. Looks like you've got a good plan.
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:great02:
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The hull does look to be ready for battle!! I wondered how you were going to reglass the weird transom those 240s have. Looks like you've got a good plan.
Rickk, Once the stringer are molded back, fuel subfloor is done and stringers capped, it should really feel stout. And yes, I pondered :think: a while (years at this point ...because I started this 240 project on a cut up cabin model Seahunter I sold) to come to this conclusion and pretty confident it will be the best way in the long run. It will definitely be a challenge getting it shaped and rub rail how I want it on the transom.
:great02:
Hey Capt. Bob., good to see you around. :salut2:
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I check in off and on. Been working on housing improvements for our two sons. Boat hasn't seen water in over two years. Priorities change and I'm not getting any younger.
Excellent progress on the 240. looking forward to the finished product.
Good luck. :thumright:
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On March 23rd I picked up a TTop tower combination that was from a Young 24. Looks to be a similar top that I have seen on a Gause as well. Really solid and got it for a great price. I tried for a while to find a frame so I could build a hardtop so this is perfect. It also has the provision for me to add a second station if I decide to do so and has a storage box built into the fiberglass top. Now just have to cut up my console to make it work.
(https://classicaquasport.com/gallery/data/946/IMG_7751.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=23826&title=img-7751&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7752.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23827&title=img-7752&cat=946)
Transom live well that they just threw into the deal( Pretty Wide and deep.....Dimensions are approx. 17x37x17 :
(https://classicaquasport.com/gallery/data/946/IMG_7753.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=23830&title=img-7753&cat=946)
The fuel tank subfloor was almost finished until I had a failure on the layup. I am pretty sure the glass was wet in one spot because it rained really bad the day before and the glass (although hiding under the hull) got damp. Got it ripped off, grinded back down and its finally done.
(https://classicaquasport.com/gallery/data/946/IMG_7769.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=23832&title=img-7769&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7779.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=23834&title=img-7779&cat=946)
These 1’’ Plascore Plastic Honeycomb panels are incredibly strong when laid up. There is nearly no deflection in a 1'' panel. Really happy with them. I did pick up a couple sheets of 3/4'' to inlay for the tower and either heavy glass thickening or 1/4'' aluminum backing.
(https://classicaquasport.com/gallery/data/946/IMG_7780.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23835&title=img-7780&cat=946)
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:thumleft:
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Got the bottom of the hull gel coated underneath the fuel tank subfloor and subfloor glassed in. I used some cut up glass panels from another project as a "Mold backer" and it worked out great for the purpose. Getting close to putting foam back in the stringers.
(https://classicaquasport.com/gallery/data/946/IMG_7832.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23837&title=img-7832&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7833.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23838&title=img-7833&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7912.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23881&title=img-7912&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7915.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23882&title=img-7915&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7916.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23883&title=img-7916&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7918.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23885&title=img-7918&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7917.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23884&title=img-7917&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_79501.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23890&title=img-79501&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_7951.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23891&title=img-7951&cat=946)
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Got around to measuring up and cutting the console down to fit the new T-Top. Need to grab a couple of sheets of Melamine to use as mold backer to build it back. I cant wait to get a deck built and start mocking stuff up!!
(https://classicaquasport.com/gallery/data/946/IMG_79281.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23886&title=img-79281&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_79292.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23887&title=img-79292&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_79312.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23888&title=img-79312&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_79321.JPG) (https://classicaquasport.com/gallery/showphoto.php?photo=23889&title=img-79321&cat=946)
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:thumleft:
That's a unique t-top the way it has 2 levels. Are you going to make the console taller so you can utilize the rear attachment points?
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:thumleft:
That's a unique t-top the way it has 2 levels. Are you going to make the console taller so you can utilize the rear attachment points? Unfortunately the rigging tubes you noted that go to the storage box in the top are not in line with the console so I will have to raise the console about 4-5 inches to make it work. I thought about raising just the helm section so I don't increase the overall height of the console but it would be much more work so I have to ponder on that. I was always into puzzles as a kid but this is next level.
The Top style is actually commonly used on Gause Built Boats (not sure if they come out of the same mold but they surely look identical) which I discovered in the process of making the decision to purchase. The top was marketed as a takeoff from a Young 24. It has a fiberglass hardtop so it makes for a usable platform. I really like the look and think it will compliment the eyebrow on the cap well. I know most like a flatcap but I like the classic look of the brow and its functionality to shed water.
(https://classicaquasport.com/gallery/data/946/2802312_f86916e0_4.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=23892&title=2802312-f86916e0-4&cat=946)
(https://classicaquasport.com/gallery/data/946/Young_24_Tower.jpg) (https://classicaquasport.com/gallery/showphoto.php?photo=23893&title=young-24-tower&cat=946)
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Summer is HERE!! And it’s more brutal than it seems it ever has been!! I'm determined to get foam in these stringers this summer so I don't miss out on the expansion opportunity of the heat (and get stuck waiting for winter to be over to foam). I'm going to be coring the hull sides with 3/8’’ Divinycell (from the chine up and forward within the bow) and capping with a layer or two of 1708 and final fairing a layer of chopped strand mat and then maybe a fine cloth for easier sanding/fairing (similar to peel ply but cheaper and works better according to a boat builder I am buying materials from).
I’ll be using the factory casting deck so it will get built back using new foam on the underside for the integrated fish box, new glass tabbing @ underside, and new Gelcoat inside the boxes and underside of gutter rails for a finished look inside. The main cockpit deck will be 1’’ plascore with 3 layers of 1708 top and bottom). I hope to core the sides in the fall/winter, set casting deck by spring of 2025, build deck mold/table and finishing/fairing by fall/winter of 2025. Don’t mind me as I brainstorm and set goals for myself LOL. On to some updated photos…
Melamine Form built & screwed/bolted to existing glass outer skin, Matt buildup, one (1) layer of 3610, and one (1) layer of 2408. The remaining layers for exterior skin will be laid now that the mold and screws have been removed..
(https://classicaquasport.com/gallery/data/946/IMG_7998.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=23978&title=img-7998&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_8295.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=23979&title=img-8295&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_8297.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=23980&title=img-8297&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_8298.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=23981&title=img-8298&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_8300.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=23983&title=img-8300&cat=946)
(https://classicaquasport.com/gallery/data/946/IMG_8299.jpeg) (https://classicaquasport.com/gallery/showphoto.php?photo=23982&title=img-8299&cat=946)
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That looks really good Ulysses, that multi-level transom is a bear and it looks like you nailed it. :thumleft:
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Rickk,
I am really happy with how it came out indeed. Molding clay was the ticket for the inside corners and the melamine works great for molding! It was my first go at a mold so glad it came apart so easily. I just wiped it all down with some partall wax (making sure not to get it on my tapered glass edges) and it popped right off.
Not I have to decide how best to set coosa because I’m afraid of just bedding it in the center without a way to get to the backside corners. I’m thinking of forming inside with melamine and pouring foam in the corners, popping the mold, and laying 3-4 layers of 1708 to build an inside “exterior” skin sort of speak for the coosa to bed into. Thoughts?
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Thanks for the chart. REALLY helpful
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Happy to help Duffy! Thanks for the "bump" and motivation to get back posting. I actually should have shared it sooner so here is the Chart Duffy is referring to...
(https://classicaquasport.com/gallery/data/24/24539-5270-IMG9156.png)
I guess part of me felt it belonged to the builder that shared it with me when they sold me materials....but but at this point.....I am happy to share that its from Mirage Manufacturing /US Fiberglass Supply in Gainesville, FL
Progress has been slow this year. Unfortunately, Mom got sick with ALS early this year and we lost her in September. Its an Ugly Disease. Life is fleeting and much shorter than we expect. Reminder: Spend as much time with your parents and family!!
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Sorry to hear about your mom. Never enough time and you always think of ways you should have spent it differently. Hard labor, like working on a boat, is always a good distraction. Through our sin we all put Jesus on the cross and because of that we all get forgiveness and comfort. It's weird, but somewhere in there is some positive.
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Sorry to hear about your mom. Never enough time and you always think of ways you should have spent it differently. Hard labor, like working on a boat, is always a good distraction. Through our sin we all put Jesus on the cross and because of that we all get forgiveness and comfort. It's weird, but somewhere in there is some positive.
Thanks for the kind words brother. I have peace knowing she is now without pain in heaven with our lord and savior!
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Got a little breeze from some of the Florida hurricanes this summer and the oldest carport, almost 4years old, gave up. Thankfully, they sell replacements for them and they are fairly reasonable and easy to replace.
(https://classicaquasport.com/gallery/data/24/24547-303-IMG8879.jpeg)
Finally getting the transom prepped to set into the outer skin..
Two (2) Layers of 1708 on the inside of the transom. Got it trimmed, grinded down and rounded edges for it to be set in core bond soon. Transom for the 240 is on right @ 1.5'' thick. The other is the transom for the 222 flatback I am also building.
(https://classicaquasport.com/gallery/data/24/24540-2080-IMG9029.jpeg)
(https://classicaquasport.com/gallery/data/24/24541-4978-IMG9136.jpeg)
(https://classicaquasport.com/gallery/data/24/24543-841-IMG9138.jpeg)
Got the inside skin grinded down and taped off to prevent the corebond to creep on the rest of the glass and eliminate a little cleanup. If all goes as planned, I should have the transom set in this week and hopefully the inside glassed in by the weeked.
(https://classicaquasport.com/gallery/data/24/24579-4955-IMG9169.jpeg)
(https://classicaquasport.com/gallery/data/24/24580-3777-IMG9170.jpeg)
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Looking good Ulysses :thumleft:
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Remotivated. Excellent.
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An additional Two (2) layers of 1708 were set in place and the core (with Arjay 4001 Core Bond troweled on) was set wet against the wet resin. Need more resin to finish the inside liner so I can tie the stringers in and start the inside hull side coring (3/8'').
(https://classicaquasport.com/gallery/data/24/24662-3941-IMG9339.jpeg)
I need to get some photos of the core set in place.
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Progress! Excellent.
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You have any pics fellow traveler?
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You have any pics fellow traveler?
Unfortunately, I do not. I haven't spent much time recently on this one. I do plan to prep the hull sides soon so I can bed the hull side coring. I I really need to get all the grinding work done before the heat is back because I cant stand grinding or sanding in the heat!
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No joke on that. Don't kid yourself, though, grinding in the cold is no fun either.
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Raised the cap this past weekend and got the strip of bonding they used between the liner and hull at the rub rail. Pointed shovel worked well for most of it again!
(https://classicaquasport.com/gallery/data/24/24764-6335-IMG9686.jpeg)
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Got the hull sides knocked down with 60-80 grit using my 7'' Dewalt polisher/sander that I almost forgot I had. It makes a mess but gets the job done and easier to control than an angle grinder.
(https://classicaquasport.com/gallery/data/24/24765-853-IMG9688.jpeg)
(https://classicaquasport.com/gallery/data/24/24766-7880-IMG9689.jpeg)
(https://classicaquasport.com/gallery/data/24/24767-8729-IMG9692.jpeg)
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Moved some stuff around in the small space I have within the carport and decided to gut all the wood (hopefully this week) from the casting deck. I obtained a bunch of 1/4'', 3/8'', and 1/2'' Divinycell scrimmed and scored coring material at a good price that I am going to use wherever I can.
(https://classicaquasport.com/gallery/data/24/24768-1999-IMG9696.jpeg)
(https://classicaquasport.com/gallery/data/24/24769-5793-IMG9697.jpeg)
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Movement is good
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Got the casting deck wood gutted out tonight.
(https://classicaquasport.com/gallery/data/24/24773-1978-IMG9701.jpeg)
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Itch much? I wish I had pulled the liner out whole. Very nice
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Itch much? I wish I had pulled the liner out whole. Very nice
Pulling the liner is definitely the way to go IMO. Having a liner is going to really help me with the finish. However, I am not sure how coring the hullsides is going to work out considering it will add thickness.
The itch + cooler evenings + compressed air shower + lathered up loofa deep scrub in the shower is the way to go. LOL!! I think my tolerance to the glass is the only way I am able to tolerate all these projects!
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That's going to be tough to core the hull sides and keep the liner. I guess it depends on how thick the coring is, whether the coring goes to the top of the hull ( to screw the cap into) and how much the liner will flex. Seems like it could be done.
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That's going to be tough to core the hull sides and keep the liner. I guess it depends on how thick the coring is, whether the coring goes to the top of the hull ( to screw the cap into) and how much the liner will flex. Seems like it could be done.
The scrimmed and scored divinycell core will stop short of the top of the hullside. There will be either 2'' of built up glass or another core material (i've seen mat/core-mat/mat/core-mat/mat used) that will hold screws for cap/rubrail. On second thought, I probably need to start with the 2'' so i dont make a mess on top of the hullside coring. I will probably test fit the liner panels when I get things finished up.
SEE BELOW EXAMPLE... NOT MY BOAT OR PHOTO:
(https://classicaquasport.com/gallery/data/24/24774-3994-14202215139441726522837826446649576525715361n.jpeg)
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That's pretty bad arse. Do it.
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That's pretty bad arse. Do it.
No Doubt! Its NOT a matter of if, but a matter of HOW! :danceSm: I met a boat building last year that I picked up the coring materials from. He walked me around some large cat style racing hulls and it was extremely impressive how strong and stiff the hullsides become with coring materials in them.
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As it turns out, I had TERRIBLE contact from the Coosa to the exterior skin. I made the mistake of rushing to bed the coosa in the coring compound right after two (2) large 1708 glass layups after MANY hours. It was in the late evening/early morning and knew I should have waiting till another day. Oh well, everything is repairable with fiberglass, right? Just throw more $$$$ at it. HAHAHA
After much thought of a repair and having to fill the void with Arjay transom pour, I decided to pry it off and redo it again. Thankfully, it had very little contact (only at the top) and after cutting the fillets at the edges with a multipurpose blade, it let go fairly easy using a pry bar stuck in the corner pocket.
Pictures AFTER Coosa was pried off:
(https://classicaquasport.com/gallery/data/24/24839-4831-IMG9759.jpeg)
(https://classicaquasport.com/gallery/data/24/24838-7713-IMG9757.jpeg)
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Chipped most all the cured Arjay bonding compound off the coosa and transom over the weekend. Used a heavy duty paint scraper and hammer. Grinded all the rest smooth and came up with some better ideas to clamp/pinch the coosa into the transom skin.