Mike's 77 22-2 Rebuild

[Tampa Bay Mike]

Picked up a late Christmas present the other day. Got a 01 200hp Suzuki with only 707 hours. Came with all the wiring, controls, gauges, and everything else it needs. It's not exactly what I was looking for but I just couldn't pass it up.

If I decide the run it, I may reconsider the livewell in the transom since it's a bit heavier than what I was originally planning for. I got it up on a stand in the shop for now so I will have my mechanic check it out in the next few weeks and make a decision.

[Marcel4t]

That's really exciting!  How much more does that weigh than the zuke 175?
I got a livewell leaning post for that reason.

[Tampa Bay Mike]

I actually have no idea. It is a V6 so I figured it would weigh more than the 4 cylinder 150 Yamaha that I have been thinking about getting but it may not. I've been trying to find some more info on it but it's hard to come by. I was mistaken though that it's not an 01, the prefix on the tag said 20001 so at first glance I thought it was. It is a little older but that's ok with me. It is super clean for its age and the price was right. (Free  )

[Marcel4t]

You lucky dog!  That's awesome.

[Capt.Joe]

Your progress is looking great! Getting a motor anywhere near that price would be a blessing. Can't wait to see it rigged. Keep it up

[perchman97]

If you end up wanting to sell it let me know, I heard there's a guy down in Fort Myers looking for a motor with a torn apart 22-2

[Onebadlarry]

Any updates Mike? Been following your rebuild like a crazy ex stalker as I appreciate your craftsmanship and documentation along the way.

[Tampa Bay Mike]

Any updates Mike? Been following your rebuild like a crazy ex stalker as I appreciate your craftsmanship and documentation along the way.

Umm, thanks I guess haha. Not too much progress in the last week or so. I picked up some thru hull fittings and hose so I can plumb the gutters. I also got some foam board and some 9 oz cloth to make some liners for inside the hatches. I figure if I'm going this far I may as well make it somewhat pretty when you open them vs just looking at the hull bottom. I started glassing them up this week and hope to have them cut out and formed up this weekend.

[Tampa Bay Mike]

Started on the hatch boxes over the weekend. They are turning out pretty nice. Will be better than looking at the hull when you open them up for sure. Just need to swing by the hardware store and pick up one of those locking angle finder tools so I can finish the end pieces. I had "borrowed" my dad's for a while but he saw it in the shop and took it back a few weeks ago. Trying to get all those angles just right is a PITA without the right tool..





I also laid up the last few gutters I will need for the front casting deck hatch and started measuring the foam to make the box for that one. I'm going to go with one big hatch vs the normal three, plus a small anchor locker.

Question I have now is, what does everyone use for the deck drains and scuppers? I looked at a few different thru hulls but I haven't seen exactly what I'm looking for. Since I raised the floor, I would like to be able to go right out the back horizontally, but to do that it's almost like I would need a custom piece with a screen on the deck side and a scupper on the outside. It seems that the most common approach is to get a deck drain and also a transom thru hull and connect them with a hose but since I planned to put the drains close to the transom it seems like that may be a little tight. Does that make sense?

[Capt.Joe]

If I were at the point where you're at now, I would use TH marines all purpose drain plugs. I'd try to seat them in the gutter of the hatch and run the hose either to the back of the boat into the bilge area or try to run the hose out of the boat above the waterline. I'd also use these plugs for the inside of the hatches and run them the same way.

[Fish Head]

NADA Guides (www.nadaguides.com) will give you the dry weight plus value of pretty much any outboard on the market if you are still looking for that info. Cheers T

[Tampa Bay Mike]

Thanks for the info on the drains and engine values. I'll check those out.

This weekend I got back at it a little bit. Managed to finish the side hatch boxes and glassed up the front one. It is big enough to get inside of so I doubled up the foam on the bottom and have three layers of glass on it since I know my kids and they are bound to get in it...



I also got a wild hair up my ass and decided that I wanted to try making a leaning post. If it works out like I'm hoping I will inset my livewell into the back of it instead of putting it in the transom. I had a bunch of 2x6 decking planks laying around so I screwed up a quick frame and cut some thin MDF panels to go inside. Now I need to get something to round off all the corners (modeling clay?) and I can start laying it up.



This is what I'm going for. If anyone has any tips on the best way to round off the top part I'm open for suggestions on that too.

[mshugg]

For the curve, you can buy laminate sheets at a home improvement store.  They’re similar to the melamine surface you’re using, but without the partial board.  They take a bend pretty well.

[Tampa Bay Mike]

For the curve, you can buy laminate sheets at a home improvement store.  They’re similar to the melamine surface you’re using, but without the partial board.  They take a bend pretty well.

Ok cool, I'll check that out. I bought the 1/8" MDF hoping I could bend it enough but it just won't make it before it starts to crack.

[Tampa Bay Mike]

I managed to get the rest of the mold finished up the other night and got it laid up last night.

Rolled some gel first



Glass cut to fit.



2 layers of 1.5oz CSM and a layer of 1708



Popped out of the mold today.



It's not the prettiest thing in the world by far but I can work with it. I made a few mistakes and learned a few lessons just like everything else so far in this build, mainly not letting the gelcoat fully cure which caused some bleed through and dimpling that I'll need to fill. The way I look at it I would have spent almost as much time trying to perfect the mold as I will cleaning it up. I think I am also going to add some core to the longer parts to keep the flexing to a minimum. In any case, one more thing almost checked off the list and I am ahead a few hundred more bucks.