86 Intrepid refurb

[dirtwheelsfl]

1986 26' Intrepid. Current project im doing for a friend of mine. Working our way up to a full paint job, but first need to address some rotted wood core issues and some delam. Also building and in deck livewell and some other small parts. New coffin cover as well..

LOTS of room in this thing







removing rotted wood core due to poor sealing. front portions had tower legs bolted to it. culprit in the stern was a rod holder







replaced with corecell scraps bedded in epoxy. ran out so just used some pvc board in the stern





any gaps filled with thickened epoxy and glassed over while hard but still tacky.







some might replace from the bottom, which would be ideal... if it was upside down. ill work WITH gravity and just fair it in. could also have used old skin and taped the edges back together, but i feel better with a full lamination with such small surface to bond into the original laminate. plus i charge hourly :)

[dirtwheelsfl]

The foam core here was all delaminated from the top skin by water intrusion through a grab handle (4 thru bolts). ground down to good core and filled/glassed.



pattern for glass





no idea how this happened, but skin and core was crushed. need to finish this first so i can get the new coffin cover on, and stop almost falling into the hole. wasted space in front of the tank bulkhead will be painted and will have an access from inside the console for storage.











couple leaning post changes apparently







all holes here drilled out and thickened epoxy injected. bad wood was localized to just a couple very bottom transducer holes. all get beveled and glassed. been told the boat originally had twins, but i think someone just changed the side the rigging came through when repowered with the e-tec, because i cannot find any evidence of a twin bracket.





im not sure why intrepid back then was vacuum bagging and foam-coring most things and then wood coring other things and not using some type of synthetic?
 Fairing starts monday!

[RickK]

Thanks for the tutorial - always appreciate this.
I see you use wax paper - why?

[dirtwheelsfl]

Here i was using it as tracing paper for making patterns for glass to be cut. Use it for a cheap peel ply sometimes too...

[RickK]

You could put my 170 in the aft of that thing and still have room - huge.  Lots of fishing room.
Trace paper makes sense since you can see through it.
Nice big carport to work under also - boy I could have used that yesterday as I was cutting out the floor of my 170.

[dirtwheelsfl]

Yea i love this thing! Wish it was here when i was doing the flattie. My grandma has it behind her house which is nextdoor. My air hose is just long enough to reach everything. Wheres the pics of your demo?!

[RickK]

Gotta love grandma  
I have been taking pics as I go and will save them for a rebuild post.  Yours is the topic here and I may pick your brain on layups and such as you go (and as i go).

[gman 82 aquasport]

How goes the rebuild , any pics of the finished product Like the idea of wax paper for patterns, will borrow that in the future

[dirtwheelsfl]

Got a bunch of pics, none too exciting though. Found more rot in the cap on the bow and console, so just fillling, glassing, fairing etc. Built a one-off livewell to drop in the deck as well.    Convinced owners to paint it white too haha!

Will update when it actually looks like somethings been done (primer etc)

[dirtwheelsfl]

More rotten wood!   This is why ANY penetration i put into wood is overdrilled and filled with epoxy.



control box mount



Lots of holes popping up when sanding started. beveled, glassed and faired..







checking fairness...



Built a livewell to drop in the deck here. The hull bottom will be the main support for it, then the flange on it will be thrubolted to the deck hatch flange. Transducer in the bottom really dictated the size and location of it, then built the rear flange/hatch divider and glassed to the deck.  Then had to cut the front hatch down and add an inch and a half or so to the rear hatch. Goal was to make it factory looking      Hatches were also delaminating on the edges, so the core got cut back a few inches and reglassed the edgesof the core to the outside skin.

[dirtwheelsfl]

Primed up..    Going from cap to console to interior, all in primer first then finish paint. Then onto the hull, which is going to white...

Another thing i did was take a fairing board to the bottom lip/edge of the cap. Youd think a boat of this caliber (price) would have nice straight trimming done there but no, it was pretty wavy. I can see some sloppiness under the rubrail but on the inside? not gonna fly. No one will ever probably notice, but i made sure the owner knows it.





heavy repair areas..

[gran398]

Beautiful work.

That high-build primer is the deal.

[RickK]

Nice work Chris  

[dirtwheelsfl]

I cant stand sloppy cuts!   I wouldnt have let her out the door...

This is the bottom edge of the top half of the 2 piece console



lip under the seat in the front of the console

[gran398]

Quality delivered

"When the thrill of cheap is long forgotten...quality still remains."