Projects shouldn't surprise you but they do.

TenE307

Petty Officer 2nd Class
Joined
Feb 18, 2003
Messages
193
Well this weekend I started my project.<br />It is a 1991 sea ray 160.<br />I thought the floor was bad, but i didnt think it would be this bad. To start it off i tried to remove the rear seat frame, but it was not coming forward. To find out previous owners solution for a soft floor was to put a new floor over old rotten one. so now have top floor and bottom floor. the bottom floor was so bad in the middle that it broke under slight finger pressure, same with the tops of the srtingers. now i have a little over half of floor and foam removed. i was wondering what is the best way to get the floor away from the hull on the sides. and whatever method i chose is that the same method for the stringers.<br />i also was suprised to notice that the support between the stringers does not go all the way to the hull edge. there are only two supports for the stringers that just run between the stringers, with foam running the whole length of both sides. once i cut into these srtingers and start sanding and/or grinding can i stand in the middle of the hull like i am currently doing with the stringers in.<br />what kind of sander/paper or grinder/disk will work best.<br />the stringers seat frames and all others are made of 1/4 plywood with a plywood lip around all edges for fastening (i think). should i change any of this or do it the same as factory with lots more resin and fiberglass atleast on the tops of the wood.<br />thanks to all other projects for the info.<br />and i am taking many pics, and hope to make a web page to help as much as they have helped me.
 
D

DJ

Guest
Re: Projects shouldn't surprise you but they do.

TenE307,<br /><br />There are many ways to cut the fiberglass away from the hull. Everything from chainsaws (yes, I said chainsaws :eek: ) to Dremmel tools.<br /><br />Use what works best for you and make sure you do not breathe that stuff.
 

LubeDude

Admiral
Joined
Oct 8, 2003
Messages
6,945
Re: Projects shouldn't surprise you but they do.

doesnt it make you sick, and want to wring someones neck when you see how the manufacturer built these boats. With just a little bit more care these boats would last a lifetime, But NOOOOOOOOOO, that might cost $100.00 more per boat. Resin and cloth really isnt all that expensive when you buy it in 55 gallon drums and the cloth in roles or you are using a chopper gun.
 

JasonJ

Rear Admiral
Joined
Aug 20, 2001
Messages
4,163
Re: Projects shouldn't surprise you but they do.

I was able to stand in my hull when it was a shell with no problems. When glassing in the new stringers you'll want to make sure the hull is as true as possible, because once the stringers cure, that is it. I did mine one stringer at a time, as each stringer cured in place, it strengthened the hull and kept it true. The 4 inch angle grinder with metal cutting wheels and grinding wheel was my weapon of choice. The cutting wheel will go through glass very easily, so you have to be carefull not to go through the hull bottom. I used heavy mat and roving with polyester resin for my project and it is more than strong enough. Epoxy works even better, it has an even stronger bond but is more spendy. All you have to remember is to make sure there is no exposed wood when you are done, and take care of it and you will be set. Good luck....
 

18rabbit

Captain
Joined
Nov 14, 2003
Messages
3,202
Re: Projects shouldn't surprise you but they do.

LubeDude – it’s probably less about the saving from materials and more about the savings from the salaries of $8-$10/hr unskilled labor.
 

outonbizniz2

Seaman
Joined
Feb 5, 2004
Messages
59
Re: Projects shouldn't surprise you but they do.

I agree with JasonJ. I used a 4" grinder with a wheel called a SuperDisk (available at Home Depot for $10).
 

JB

Honorary Moderator Emeritus
Joined
Mar 25, 2001
Messages
45,907
Re: Projects shouldn't surprise you but they do.

Hmmm.<br /><br />In my experience that is what project boats are all about, Ten.. .surprises.<br /><br />But I have been fortunate. All of my projects have been Boston Whalers.
 

TenE307

Petty Officer 2nd Class
Joined
Feb 18, 2003
Messages
193
Re: Projects shouldn't surprise you but they do.

well last night another surprise.<br />i was noticing where i stand in the center of the boat, there is a flat spot. that flat spot is not hull. i noticed how there were foam plug holes wich are leaking a slight amount of water coming out of it. now i think my only solution is to do one side stringer at a time then do the bottom stringer. these stringers are like none of the other pics i have seen from other boats.
 
Top