82 aquasport osprey 19.6 rebuild

[gman 82 aquasport]

Been a few days since posting on this, so here goes, if you have seen my new post from earlier today you can guess how the floor went this weekend, Murphy and his briefcase full of laws showed up....but I preveiled in the end even if it did get a little testy Sat afternoon..
floor glued down and screwed down
Tabbing at the bow, 8in then 4 in over it.
Tabbing down the port side, same as bow.
Tabbing at the stern.
Before tabbing was done I mixed some epoxy and woodflour semi runny, put it in a gal size ziplock, cut out a corner and used it as a pour bag, squeezing out the mix into the void around the floor, this filled it to the floor level :)
Then mixed a thicker batch to build small radius between floor and sides, the thicker mix flashed quicker(about 10 minutes) so this was done in stages

[gman 82 aquasport]

Continued from Saturday, this is where I got over my head, I got the first layer of 17oz bi-axial down, 1 run bow to stern and a narrow run to fill in the approx. 18in gap left....This is where I should have stopped and picked it back up on Sunday and I would have been fine, but no, I don't listen to good advise and I tried to lay the 2nd layer(6 oz) over the first while still wet to try and do a wet lay up.......Well guess how that turned out, not to good...
I got the bow section down, I had laid plastic over the 17oz so I could stand on it and started laying the 6oz, then things started sliding around it took about 1 hour to get the first piece in place without airpockets or wrinkles, than I started on the next piece which would go over the tubes, after wrestling with it for a while I got pi$$ed and just pulled that whole piece up and tossed it...I let it dry over night ,then went out Sunday and sanded all the bubbles and wrinkles  out and filled any voids with glass and epoxy then cut new pieces for the rest of the floor and put it down, cost about $40. worth of cloth and about a gal of mixed epoxy to fix my screw-up...

this is where I started over on Sunday


Stern after all the glass is down


Finished floor, i will do a little sanding in a few spots, nothing major , just to get a few places a little smoother...

This last pic is of the stern before any glass was applied

the piece under the floor was screwed from both sides and epoxied. the new drains will reside here.  it's not perfect but it is solid and thats what counts :pirat:

[Capt. Bob]

G Man....
I have yet to see a perfect Aqua from the factory.

[gman 82 aquasport]

Understand that, I should have some time this weekend to start sanding for the flairing and cut the middle hatch down to it's new size. Checked the floor last night and it's good and solid, no flex. Need to drill out for new floor drains on the stern, have my new brass for the drains... coming together, just detail work and paint..

[gman 82 aquasport]

Been about 2 weeks since posting on the floor job, got it down and started sanding some rough spots ans refilling with glass anything that got sanded thru the top layer of glass, then started flairing the parts that needed it, will have to say US composites flairing sanded much better than I thought it would..flaired all the edges where new glass went up the gunnels and around the new area up front and the stern..Got it all fairly smooth, you never really know until paint hits it.Here are some pics before the paint goes on, masking everthing off and covering the rest of the hull with plastic, cause I am spraying the hull.]

stern before new scupper holes drilled


bow area


from the stern


my cover for the pipe exit, took a 2x12 and made a form, covered it with packing tape ang gave it 3 layers of 6oz glass.


starboard side


port side. :pirat:

[gman 82 aquasport]

Now the after pics :)
Bow
Port side gunnel
from the stern
Starboard side rear
From the bow, you can see the new scupper holes I got drilled yesterday..........I have a few places that sagged a little, I will sand them tommorrow and reshoot when I paint the hatch covers,  overall spraying it was easier than the roll and tip method..
The floor wil be painted when I pick up my non skid paint, it will be rolled and sprinkled... :) Overall it's a 20ft paint job, looks good from 20 ft, upclose you can see some particles in the paint and some sags, but not bad for a backyard paint job with no spray booth.... :pirat: Scuppers only wound up being 2 inches higher than original..

[love2fish]

Looks good! I'd think 2" of more clearance on the scuppers would help out a lot! Unless your boat was really soaked or you have a bunch of people in there. the pictures of the spray job look good! Did you have prior experience with spraying? What paint and sprayer did you use?
you're in the home stretch now!

[gman 82 aquasport]

It was soaked, all the foam was water logged..Yeah I've sprayed a few things, 2 boat trailers, 3 landscape trailers, my 97 Tahoe, rebuilt my Captains 77 C-J 7, 2 years ago complete teardown and rebuild, new paint and a whole lot of body work, fiberglass is easier than metal..Used a campbell-hausfield HPLV sprayer, can't beat them, don't use as much air , it's gravity fed(paint cup on top) not as much overspray. Start with a thin tack coat, then each coat is a little heavier, let it sit some between coats,not enough to dry, but it needs to be tacky so the next coat will stick, to wet and it's run time, but if you have enough paint on it you can wet sand and buff it back out..Paint is from West Marine, Brightside white # 4359 I think, it took about 2 quarts to get 3 coats, I did thin it 10% so it was easier to shoot..Primed anything that had been sanded back to raw glass and anything new..Like I said it's a 20 ft paintjob but it only cost me about $150 in materials, so I'm not unhappy about it....
Floor is raised 3/4 inch and the scupper throph is 3/4 lower than the floor,  so they got raised and only 2 got put back, didn't see a need for the one under the motor..

[dirtwheelsfl]

Floor blended it nicely it looks like. Looking good!

[gman 82 aquasport]

Thanks dirtwheelsfl, it's not bad,not perfect either, but any places that are noticeable can only be seen if your on the boat or standing at the sides looking in or at the stern looking in, don't think that will be a problem while in the water :)
Love2fish. update on materials, the paint is Interlux Brightside #4359 White, used Interlux primer as well, my spray gun is an Ingersal-Rand HVLP. The blue is a custom mix, ordered some sky blue from west marine and when it got here it was way to blue, so mixed it half and half with the 4359 white and got the lighter shade of blue, almost Carolina blue..
Going to paint the hatches and gunnel covers tommorrow and try and get the nonskid cown as well, then buff the hardware Sat while at work..should start mounting things back on next week if I have the time , got a couple of side jobs coming up and everybody wants their stuff done by Easter

[Capt. Bob]

not bad for a backyard paint job with no spray booth.... :pirat:

Function over form... that's what makes it great.

Gotta love it.

[gran398]

Lookin' Great!!

Plan on bringing it to the reunion

[gman 82 aquasport]

Planning on it, plus I will have it in Southport some this late spring and summer, we plan on taking it down when I have 3 weekends off in a row, leave it at the in-laws and go back the following week and use it and bring it back home for lake use.. :pirat: Ran into a small issue while putting the nonskid down yesterday...epoxy based nonskid going over polyurethane paint caused a small reaction around the edges of the floor where the non skid wrinkled up.... solution is to sand the nonskid, skim coat floor with flairing compound and sand then repaint nonskid over....it's all fixable and more fun the second time, what's perplexing is that I sprayed the hatch covers with same paint and shot the top edges for blending and the non skid didn't wrinkle on those, go figure But after talking to some buddies who do industrial coatings and paints they told me how to fix the situation

[gman 82 aquasport]

Long time -no post , Got the floor finished, all non-skid down and have all new covers for all access holes installed. Still have to blend in paint on transom, as soon as no wind to screw it up. Going to post pictures on Wed. About have the trailer ready to put boat back on it, then re-install console(freshly painted)and t-top( new braces)and hatches. New eyelets front and rear, polished all the other shiny stuff. Will use all new wiring and run hydraulic lines for new Seastar steering.New fuel lines. Mother nature hasn't been cooperating much lately, and when she has the Mrs has had other plans, what do you do So far she hasn't asked for any reciepts so I won't complain  

[dburr]

Mother nature hasn't been cooperating much lately, and when she has the Mrs has had other plans, what do you do So far she hasn't asked for any reciepts so I won't complain  

    Good heavens man keep your head down and mouth shut other then to say "Yes Ma'am!"