88 Thompson 190 cutlass repair/restore

Miglater

Cadet
Joined
Mar 31, 2012
Messages
12
88 Thompson 190 cutlass w/ 3.7L merc.

My grandfater purchased this vessel new from Anderson Marine at the boat show in detroit. It spent most of it's time on a hoist and mainly used for drift fishing on the St. Clair river, being on a hoist while not in use was a good thing as the plug was always out and any rain that fell didn't reside in the boat for long. Winterization was always performed and the boat sat on it's trailer next to the house tarped and drive covered.

All the paper work for the boat has been kept from bill of sale to the tach installation instructions, Merc shop manuals and parts catalogs were also ordered with the boat for engine and outdrive.

Now for the the not so good :p

After my grandfather died, my father inherited the boat, we used it 2-3 seasons and then on one trip it became apparent that there was water in the fuel. Got a tow from canadian coast gaurd, loaded it on the trailer. Boat has been out of water/use for atleast 10 years, 2-3 years outside and the rest sat in a pole barn covered, some time during all this non-use/storage, an attempt was made to start the boat on muffs, then it was determined that water had entered the drive and locked it up, would not turn over. So he replaces the alpha 1 with a pre-alpha that has apparently been rebuilt. Tore up the floor to remove and re-seal fuel tank, floor had a sort spot so new floor was installed. During all this fun with replacing floor and tank resealing some algae took up residence in the carb. A rebuild of the carb was attempted and failed.

Last fall I got a call from my father, saying that he is giving me the boat due to him not having any means to transport it to texas when he moves. Says it needs some carpet and a carb. For the sentimental value alone I accept the boat.

Got the boat home in the drive way, removed carb for dis-assembly and inspection, washed and waxed a somewhat chalky and oxidized gelcoat, I think it needs some really good restoration compund but is acceptable at this point given the age. Cleaned and treated the vinyl, also came out ok, just wanted to start taking care of the boat properly.

The winter was very mild and I had the itch to uncover the boat and get to work, 2 weeks ago I moved the boat to a place i can work on getting it sea-worthy, First thing planned was to get it running so, carb parts were ordered over the winter and a nice long search for a new power piston assembly. I was relived to find one on ebay. That was the part my father couldn't locate during his attempt to rebuild the carb, Mercarbs are expensive to replace. My brother who helped install the replacement out drive noticed the bellows were cracked and had asked if my father was relacing them, His reply was that they were pretty thick and should still be good.

I inspected the bellows and found the exhaust one was completely separated, new bellows, u-joints and gimbal bearing kit was ordered and installed. The u-joints appeared to be new and did not get replaced as this was a rebuilt drive that has not been used, I intend to pressure test the drive before putting it back on. I drained the fluid and it looked new, no evidence of water. I found an alignment tool for gimbal to coupler for $30 and waiting for delivery, Also ordered upper shift shaft bushing and oil seal as there was some play in it. Shift cable seems to be in good shape. Once the carb is back on and the drive is re-installed I'll put some fuel in the tank with some stabil, I'm betting water got in the tank originally due to a bad filler cap gasket/nylon ring, gunna replace that as well. I then hope to start the engine on muffs, let it reach operating temp and inspect for leaks. I've heard the 3.7's like to warp the head so we will see. I have yet to check the stringers and transome, I'd like to think the stringers are ok and that my father checked them when he had the floor out. Also remembering that the boat has always been out of the water with the plug out.

I do realize now that i should have checked the stringers and transom first but, my plan is to check the engine for issues so if i need to do structural repair i can repair the engine during that time while it's out. If for some miracle everything checks out and goes well. Carpet will be ordered/installed and the interior will get put back in. Will flush the coolant before sea-trials.

The trailer is not original and not adjusted properly, has 2 broken keel rollers and bunks that need adjusting. The bow stop needs to be lowered and moved further back, theres some marring of the bow from this above the winch eye, i will get some pics of it on here for advice of what needs to be done to repair it. I'm an automotive technician so glass isin't my specialty.

I've certainly have my work cut out for me and probly forgot a few things but i'm sure you get the idea. A big thanks to all those that have posted all this stuff i have been reading about on this forum all winter while preparing/planning this project. I really have learned alot here and hope to build on my knowledge and share some stories aswell.
 

Bondo

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Staff member
Joined
Apr 17, 2002
Messages
71,241
Re: 88 Thompson 190 cutlass repair/restore

Ayuh,... Welcome Aboard, 'n Good Luck....

I'd change the lower shift cable while ya got it apart,... It's old, 'n no doubt needs it...
 

Miglater

Cadet
Joined
Mar 31, 2012
Messages
12
Re: 88 Thompson 190 cutlass repair/restore

I went out to the boat today with hopes of drilling to inspect transom, stringers and motor mounts but it was too cold imo to seal the holes after drilling. Spent some time repairing the trailer lights. Inspected the fuel filler cap nylon seal and was not suprised to see it had split. Replaced it and was out of stuff to do til the alignment tool is delivered along with shift shaft bushing and oil seal. I did remove the old ones but that only took a minute.

Bond-o,

Is there a way to tell if the shift cable is bad? I had the core of the cable out and inspected it while replacing bellows, I'm no cable expert but there was nothing i could find that was out of the ordinary, it was not rusted, moved very smoothly and had no kinks or bends. It did not seem to be stretched from what i could tell.

Is there something else i should look for? I don't mind replacing the cable if i can find something wrong with it to justify replacement.

Thx again o7
 
Joined
Jun 3, 2012
Messages
11
Re: 88 Thompson 190 cutlass repair/restore

I would love to see an update to this, I am looking for my first boat, and it's a thompson that has sat for 8 years. What issues you find might be what I'm headed for.
 

Miglater

Cadet
Joined
Mar 31, 2012
Messages
12
Re: 88 Thompson 190 cutlass repair/restore

Update as requested and long past due :D

I got the bellows done and drive back on, filled with lube. Had the battery on a maintainer all winter, installed into boat and seemed to be okay till i tried to crank it over to get some oil pressure before trying to start the engine. Hooked it up to jumper cables and it cranked! Oil pressure came up. Then i noticed a leak from the oil filter. Whoever put that filter on there must not know what over tightened is. Replaced the filter, got fuel up to the carb and manually filled the bowl. Double checked the hose was on and muffs positioned correctly. Crank and no spark, replaced points and condenser. She fired up and i had a insta-smile. Sounds good and idles properly, nice and smooth. I let her run for awhile and found the radiator cap needs replaced.

I've drilled into the transom and front motor mount area, front mount looks good, transome will need replaced, gunna do the deck, stringers and transom next spring with tax returns. It's getting splashed this season and babied on some inland lakes. The transome isin't completly bad but it has started to go and it certainly won't get any better on it's own.

To-do list before splash....

Repair trailer keel rollers. In progress, should be done this weekend.
Test bilge pump
Registration. Doing this wed.
New radiator cap
Tune up and oil change
Put seats back in, not sure what to do for carpet as i'm gunna redo it next spring.
Coolant flush
Check exhaust flapper
New battery and install battery tray/box
Adjust shift cable
Check the ropes
Insurance


To-do list after splash......

Check for leaks
Update the radio! haven't seen an analog fm stereo/cassette player in atleast a few years, lol
Update from generator/regulator to alternator
Update ignition from points to electronic


I've got alot to do but i've got the itch to get out on the water. My brother did a fantastic job on the carb. He is also doing the welding of the new tabs to the trailer for the keel rollers. We made the tabs ourselves using 1/4" thick steel by 2" wide. Tools used for this was, sawzall, air drill, bench grinder and a small piece of cardboard for a template.

I'll try to get some pics of whats goin on this weekend.
 
Joined
Jun 3, 2012
Messages
11
Re: 88 Thompson 190 cutlass repair/restore

good job and thanks for the update. I think we stumbled on a freaking sweet deal, so I wont be going after a thompson (for now) but I've been reading almost everyone's rebuild threads. IF the thompson is still there this fall, and you have had good luck with your's, I might go after it for a winter project. Because I don't have enough projects going on...
 

Miglater

Cadet
Joined
Mar 31, 2012
Messages
12
Re: 88 Thompson 190 cutlass repair/restore

Time for pics

First day

b2.jpg

Thompson

b4.jpg

Rebuilt drive

b6.jpgb13.jpg

Bellows and gimbal installed

b16.jpg
 

Miglater

Cadet
Joined
Mar 31, 2012
Messages
12
Re: 88 Thompson 190 cutlass repair/restore

More

Getting ready to see if it'll run

b11.jpg

It runs! Now onto carpet and interior.

b12.jpg

Carpet befor glue down and some upholstery repair.

b3.jpg

Some more removal to do

b14.jpg

Carpet glued down, seats in, most of em anyway :p

b7.jpg
 

Miglater

Cadet
Joined
Mar 31, 2012
Messages
12
Re: 88 Thompson 190 cutlass repair/restore

I didn't buy enuf to do the whole floor and sides but, honestly it's getting torn out next spring, replacing deck, stringers and transom so it's good enuf as it is to get by till then. Yeah, it's 2-tone......

b18.jpg

925CCA Battery, had to cut the new tray in half to make it work with the wider battery.

b10.jpg

The custom made Eagle boat cover is still in decent shape after 22 years. Although theres a few snaps that need replacing on the center section of the windscreen.

b5.jpg

New keel rollers and registration stickers.

b8.jpg
 

Miglater

Cadet
Joined
Mar 31, 2012
Messages
12
Re: 88 Thompson 190 cutlass repair/restore

Got the rest of the interior cleaned and put in.

b1.jpgb15.jpgb17.jpg

Did an oil change. I ordered an exhaust shutter today, found the old one to only have half of one flap remaining. Still have to secure the engine box, hook up shift cable and adjust it. I put it on the muffs again today. Had it on jumper cables last time due to a bad battery so needed to check that it would charge. It does \o/ Still have to finish welding the new tabs on the trailer for the keel rollers. Hoping to get this done wed. I wanna take it to a launch so i can check for leaks on wed. Fathers day is the anticipated splash day.

Almost forgot i have some video of the first fire after years of sitting.

 
Last edited:

adje

Recruit
Joined
Jan 24, 2013
Messages
1
Re: 88 Thompson 190 cutlass repair/restore

Hi,

Maybe this is interesting for you to take a look at. I've just started with this website for our Cutlass 190 - 2,5 today and wil try to fill it with more interesting pictures shortly. The website is in the Dutch language.

NoWay 2.0 Thompson Cutlass 190

Looking forward to hear from you about our litle project.

Ed
 
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