1974' Aquasport 240 CC Rebuild

[Ulysses485]

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....


Some of the listing photos:

[Ulysses485]

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):



Fuel Tank Removal:


There was a bed of foam that the fuel tank was laying in. Completely saturated in water.


After foam was removed:


Almost felt like i was gardening. Never thought i would need a shovel in a boat.


Debris removed:


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. 


THERE IS EPOXY BARRIER COATING THAT WONT COME OFF WITHOUT SANDING: 



AFTER SANDING:

[Tampa Bay Mike]

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.

[Ulysses485]

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

[Treefish]

Really cool boat.  Can't wait to see the finished product. 

[Ulysses485]

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)….




Still have to get to the Starboard side...:/ I might be trying out the Citristrip paint remover.



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).

[Ulysses485]

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.
 


Main deck cutout, casting deck removed, and transom splash/storage/bait well removed.




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.




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.



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)

[RickK]

Looks like you have some good plans (and a huge fleet)

[Ulysses485]

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:


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.


Foam removed (this was 6 bags already filled):


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):




Love those smooth radius lines of this hull:



Clean up of all foam and ready for a grinder/sander to prepare for rebuild of bulkheads, stringer tabbing, etc.

[Ulysses485]

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

[Capt. Bob]

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.

Coming along nicely.

[eorr0088]

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? 

[Ulysses485]

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.

Coming along nicely.

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.

[eorr0088]

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.

[Ulysses485]

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. 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.


Transom gutted after rear stringer section was more structurally connected to hull:



Mockup of the transom melamine "mold":








Casting deck Prep. Removed all the poorly tabbed storage boxes to respray with gelcoat and glass/insulate back on casting deck:



Cut the sections of the console where many holes were to lay back flat glass in one shot against some melamine mold:



More hull bottom glass build up progress  and beneath stringers: