1999 Aquasport 245 Rebuild

[billy626]

Hi all,

Posting my rebuild progress with my '99 Osprey 245 in hopes it helps someone one day. Little back story on this boat:

Purchased the boat last year for a great deal, knowing it had soft floors. I thought it had a few seasons left of use, but after watching the T top sway all summer, I knew it was going to be a winter project. I purchased the boat in its original green, which I quickly changed to the blue you see now. I also put my twin 225 Hondas on the back (which is definitely overpowered, but she still sits flat!)

Tore the floor out this weekend. Balsa cored deck between the upper and lower mold. Going to replace the floor with either Coosa or ACX Ply fiberglassed on all sides. This will be my 5th boat rebuild in the last 10 years - but my first Aquasport. I tell myself each time it will be my last. Let's see if this one is true!

[msteinkampf]

Thanks for sharing those pics - I like seeing the original details of how the fuel tank was mounted. One question: Did the fuel tank compartment have a removeable cover, or did you have to cut the deck to get to the tank? It looks like the cover is removeable, but I thought Aquasport got rid of the removeable cover in 1994. My 1995 Explorer 245 didn't have a removeable cover.

M 

[RickK]

@billy626 - I like the hull paint color. Looks nice.

[billy626]

@msteinkampf No, the tank did not have a removable cover. When the mold was casted, they outlined where the tank is (incase it ever needed to be cut out) - but not removable. Thankfully my tank is still in good shape - going to give it a good clean before putting the new deck in

[rhtrades]

great work.  are you going to be expoying the old non-skid back after you do the core or are you creating a completely new deck?   would be interested to know how you create a non-skid diamond pattern if so....

[billy626]

great work.  are you going to be expoying the old non-skid back after you do the core or are you creating a completely new deck?   would be interested to know how you create a non-skid diamond pattern if so....

@rhtrades I've got a Fiberglass guy out of Springfield MA - Joe at Merton's fiberglass supply who I buy all my stuff from. Hes great - been in the buisness for a long time. I talked to him at length about that subject and decided to create a new pattern to the deck. The old deck had some gouges and wasn't perfect, so decided to scrap it. I will be sanding down the deck bow to stern to create a new pattern the whole way through so it looks uniform. Unfortunately getting it back to a patterned finish like you see from the factory isn't possible without the mold.

He showed me a cool technique of using THIXOTROPIC POWDER - also known as Cab-o-sil, adding it directly to the waxed layer of gelcoat to get a rough scratchy finish. It comes out looking something like a popcorn ceiling (not quite as rough obviously). When mixed with waxed gelcoat, it creates an even, hard finish that will last much longer than painted non-skids. Should be great! Will post more pictures

[rhtrades]

Thank you @billy626.  I'm in eastern MA....perhaps if i'm ever out that way i should check them out. 

That's an interesting technique.  Would love to see how that turns out.  Keep posting pics of your work!