1993 Sea Ray 200 Complete Floor and Stringer Replacement

[Aggieboater98]

I bought a 1993 Sea Ray 200 on the cheap knowing it would need extensive work but did not know the extent of it until I started demoing the seats and realized that one of the two previous owners knew about the rot and did a really cheap fix and tried to cover up the rot problem and ignore the fact that the floor was trashed. I am new to doing this type of work and have been reading a lot and watching as many videos as possible to take this step by step to make it right. So any and all tips, suggestions and advice is welcome. I will post pics as soon as I am able to.

As of this far I have about 80% of the floor, stringers and foam out, I pulled the engine and outdrive last weekend, the floor is trashed and the stringers and bulk heads are in the same shape. The foam is completely saturated in water, so taking all of this out right now is a lot tougher than I thought it was going to be.

 

[Aggieboater98]

The biggest things that I am wondering about right now is trying to find the most efficient and cost effective way to glass everything and what materials are out there that would allow for that. I do not want to use epoxy with no experience using it and wondering what would be the best to go back with on the deck once I am ready to glass it in and what would be the best thing to put down since I do not want to go back with carpet.

If anyone can answer those questions that would help me out a lot.

 

[Scott Danforth]

welcome aboard

read all the links, start with link #14 https://forums.iboats.com/forum/boa...r/295740-how-to-s-and-other-great-information

nothing wrong with carpet if its done right....go back to link 14

 

[Woodonglass]

Check the 2nd link below in my signature. It has a LOT of good info. This link will help too

View attachment iBoats MaterialsList.pdf

 

[Aggieboater98]

So I have all of the deck, stringers, foam and half of the transom out, I just need to cut out the remaining part of the deck on the sides and grind everything down. The motor mounts were not in good shape, the starboard side mount was all still intact just wet and the port side mount was rotted out where the plywood was. The demo is hard, hard work and time consuming, I didn't realize that foam could hold that much water and become that heavy. I will post pics later today.

 

[sheboyganjohn]

Before you start cutting anything more out, take measurements and lots of photos. You are going to want to try to at least put the motor well back to the way it was. The rest of the boat it is a good idea to put the general structure back where it was. If you scroll through my sea ray rebuild in my signature you will get an idea of what is ahead.

 

[Aggieboater98]

I’ve been trying to upload pics from my iPhone and it keeps telling me the files are to big. How is the best way to upload pics on here?

 

[sheboyganjohn]

I do everything from the laptop. I use the upload attachment, which is the button on the upper right next to the A button. It will upload just about anything then you can put the picture directly into the post and it will size appropriately.

 

[89 resorter]

I take the pics with my iPhone then email them to myself. Before I hit send, the phone asks what resolution I want and I simply pick one that IBoats will take.

 

[Aggieboater98]

Ok, so I started the grinding process and it is some hard, hard work. I thought about getting a cheap poly suit from Harbor Freight and it only lasted one day, I used for two days but the second day it ripped real bad and let glass in. I bought a diamond grinding wheel to take all of the bondo pink stuff down and it is working like a charm, so that way I am not going through the grinding flapper discs as fast and spending a ton of money. I'm still working on getting pics to upload, at this point I'm having difficulty in doing this for some reason.

 

[sheboyganjohn]

There is also a minimum post count before you can post pictures. I just remembered that. It is low, like 5 or 10.

 

[Aggieboater98]

I'm about 80% done with the grinding process, it is one tough job. The heat is a killer in the tyvek suit and it just drains me and makes it to were I can only last a few hours each time. So hopefully this weekend I am able to finish the grinding process and get moving onto another part of this rebuild.

 

[kcassells]

I think you can around pics by taking a cell pick to your em then copy paste.

 

[Aggieboater98]

So it's been a very long time since I started this process and have done any kind of update. I finally started the rebuilding process in February and there are so many little steps with a rebuild that it takes so much time. I am to the point of just finishing the front seat rebuild and about to start the glassing in process to complete the front seats.

So far the hardest thing that I have encountered is not knowing the correct amount of material to have ordered for this project. My budget has been blown and I'm more than committed now. As soon as I get the posting pictures situation out I will post pictures of my adventure so far.

 

[Aggieboater98]

The main thing that I am concerned about right now is finishing out the interior with gelcoat, I want to make sure that I get a good surface and it not all be uneven and to were you see all of the glass transitions.

 

[Scott Danforth]

So it's been a very long time since I started this process and have done any kind of update. I finally started the rebuilding process in February and there are so many little steps with a rebuild that it takes so much time. I am to the point of just finishing the front seat rebuild and about to start the glassing in process to complete the front seats.

So far the hardest thing that I have encountered is not knowing the correct amount of material to have ordered for this project. My budget has been blown and I'm more than committed now. As soon as I get the posting pictures situation out I will post pictures of my adventure so far.

you must multiply your time by 4 and divide your money estimate by 0.2 (or multiply by 5)

to get a good estimate on purchasing materials.... see link #2 https://forums.iboats.com/forum/boa...r/295740-how-to-s-and-other-great-information

some good rules of thumb that I tend to use

typical run-about restoration is between $2500 and $3500 not including upholstry. this is PPE, incidentals, wood, cloth, resin, fairing compound, hardware and solvents
if you must gel the exterior, add about $600-$1000 in materials (this is just materials)
if you have a cuddy cabin, add $1500 to that for cabin work
to do the interior of the typical run-about from the windscreen back is about $2k
to do the interior of a cuddy cabin, add about $600-$2000 to that
a bow rider, is about the same as a cuddy cabin
to rebuild a motor, estimate $1500-$2000
to rebuild a drive, estimate $500-$2000

if you add lighting, stereo equipment, GPS, etc...... add to that.

 

[Aggieboater98]

So I plan on gelcoating the interior of the boat and not putting any carpet down. I already have put two layers of chopped strand down on the deck and as soon as I finish getting the front seats glassed in I will be ready to sand everything down. My question is, do I need to do the fairing compound for the deck of just gelcoat after sanding? I have zero experience with this and not sure what I should do.

 

[Aggieboater98]

Well this past weekend I got the gelcoating done and it turned out great. I did two layers with the 2nd and final coat having surfacing wax added to it. I am now onto the next step and that is installing the motor back into the boat this coming weekend.

 

[Aggieboater98]

Well I got the motor and outdrive back on and only took two days to get that completed. It took me about 3 hours to get the motor level and that was a lot of getting in and out of the boat, needless to say I slept good that night. A few days later I went to try and get the motor started and after trying for 30 mins or so I came to realize that my electronic fuel pump was not working. So now while I wait for the new one to come in I am starting to redo and install my backseat supports and start to get the vinyl for the upholstery work figured out.

 

[Scott Danforth]

If the fuel pump isnt marine, do not use it. Airtex (carter fuel systems) and some high end holley pumps are the only SAE 1171 compliant fuel pumps that I am aware of