95 FW 240 Horizon Restore

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anthonysjo

Seaman
Joined
Mar 10, 2009
Messages
51
After a bunch of reading and some free time I am finally getting started with my restore project. I have the decking removed and the rotten stringers out. Pictures are below:



 
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anthonysjo

Seaman
Joined
Mar 10, 2009
Messages
51
Re: 95 FW 240 Horizon Restore

Now for the questions:
There are a few small spots where wood rot started and I am trying to not turn this thing into an entire stringer rebuild. Can I use CPES or is there something else to treat these spots?
With the wood cut and ready to be reinstalled is the right process to grind and clean all the bonding surfaces, pretreat the wood with Resin, install stringers in PB, coat with one layer of CSM, then a layer or 2 of 1708? Can I use CSM instead of the 1708?
As you can see in the photos I did not have to pull too much of the foam out 3" or so to the side so I had room to work. Do I need to use the pour in foam or can I just use exterior window and door foam?
on the decking I did not get to see exactly how the old deck was installed due to some previous repair being done. my question is this...do you normally cover the gas tank? I can see where this would be huge in keeping water out vs. having an access area but want to be sure. the Fuel cell area is 5' long so too long to lay a sheet across the boat and hit the cross stringer. I could lay two down each side and have a seam all the way around the fuel cell glassing in that seam and then use a full sheet for where the captain’s chairs and walk thru is.


I will post pics of the stringer plywood repair shortly....
 
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anthonysjo

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Mar 10, 2009
Messages
51
Re: 95 FW 240 Horizon Restore

Also I would like to know any good ideas to get a template for the decking. I bought some 1/2 foam board that I could cut easily, move around easily, and be less costly if I mess up. For the decking I was planning to put back 1/2 sanded pine that has the outdoor glue. I did think about bumping up to 5/8 or 3/4 but the 1/2 will match the decking in the rear of the boat that I did not have to remove. I also thought the foam would help with any flexing since it is setting directly on the stringers and foam.

Thanks for everyone's help in advance!
 
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anthonysjo

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Mar 10, 2009
Messages
51
Re: 95 FW 240 Horizon Restore

Thanks WOG! I am getting a little antsy as I am planning to do 5 hours of work tonight so I want to make sure I am on the right track.

Any feedback on how I should do the deck layout and specifically how I deal with the gas tank area? Do I build a removable cover or just lay over the tank and cut into it if I have to down the road? Pics above should help.

Additionally there are a few small spots where wood rot started and I am trying to not turn this thing into an entire stringer rebuild. Can I use CPES or is there something else to treat these spots?

As you can see in the photos I did not have to pull too much of the foam out 3" or so to the side so I had room to work. Do I need to use the pour in foam or can I just use exterior window and door foam?
 
Woodonglass

Woodonglass

Supreme Mariner
Joined
Dec 29, 2009
Messages
25,929
Re: 95 FW 240 Horizon Restore

CPES is worthless IMHO. All wet Rotting wood should be replaced. It cannot be repaired. I would replace the Deck the same way that it was. I really don't see a need for a hatch. If you ensure that the tank is clean and all the internals are working correctly or better yet replace them now while you can, then I see no reason for having easy access to it. After to replace the deck in a proper fashion, if you maintain the boat well, and keep it out of the elements, the deck and everything below should remained sealed for decades. The Foam in a Can is of no value and should not be used in my opinion. I would use the Blue or Pink slab foam from Lowe's and cut it to fit the areas needed. Seeing how you are scabbing in your pieces I would Highly recommend that you use Epoxy for your rebuild. You will need the added strength that it provides. If you decide to use it then you will not require Fiberglass mat, only Cloth. I'd use 17 or 18 oz biaxial weave.
 
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anthonysjo

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Mar 10, 2009
Messages
51
Re: 95 FW 240 Horizon Restore

My heart sunk a little tonight. After some good advice from the forum and WOG I was well on my way to repair but little did I know I was on the RIVER OF DENIAL. As you can tell above I am into my project already and thought I was ready to start with the decking, in fact I just fitted and cut the front most part for the decking and man I must say it was easy, 30 min or less, thanks WOG!

After that went well I felt a little guilty and thought hey why not take a few more samples and lets really go after the trouble areas at the BOTTOM of the stringers. It was a good idea with bad results. I started removing foam and it looked ok. Most had less than 1/2" of water in the foam and some with nothing at all.

Let's dig further into the wood in the gas tank area and sure enough a wet stringer. Wood was still solid but wet and that means rot in the future. I moved forward past the bulkhead and again wet wood. Oh no! I then moved past the walk way which really should not have much water and again wet wood. Oh $@&?! now I am in trouble. I have a 24' boat that needs a lot of TLC.

To keep this post from rambling let me summarize my options as I see them (feel free to give me new ideas and or shoot hold in mine):

1: Sell the boat and take the loss of $2,500:facepalm:
2: Fix it up best I can and sell it off looking like a new boat:behindsofa:
3: Tear into this boat and make a nice "new"24' boat for years to come :confused:

I hate losing money but maybe the right call. I have $2500 in the boat no trailer and it has the 95 OMC motor and out drive which does cross ref with the Volvo Penta. Option 2 is off the table. I don't think it would be dangerous today but who knows in two years.

The last is intriguing but need to really understand what I am getting into. Here is what I am thinking I will have as estimates:
$2500 original cost
$2000 + alot of my time stringer and decking restore
$2000 in hull/cap repair and paint. Guy trading me doe work so he is thinking less than $1000 in materials
$2000 in new upholstery (father is upholster)
$6000-$8000 new power pant and drive (optional)

That puts me at $9000-$17000 for a new boat. Not a bad price but what can I get ie for and can I get one in good shape?

Thought?? Put downs? Encouragement?
 
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anthonysjo

Seaman
Joined
Mar 10, 2009
Messages
51
Re: 95 FW 240 Horizon Restore

I did a little checking as I am getting nervous that I am sinking too much into this boat and I am concerned I don't have enough time. To address the TIME issue I talked to a shop that does boat repair and he is thinking in the $2-$5 k range to fix the boat up to new on the stringers, floor, and potentially the transom. I have to bring it by to get an estimate and he also said I could save a lot since I have some of the hard work done.

What are the risks of going this route and what should I ask/look out for? Not sure I will but worth checking since time is such an issue.

I asked this question earlier but is this boat even worth it? I don't have any sentimental value but I like the layout and size of the boat and I am concerned that I could try to buy another one but later find myself in the same situation with more out of pocket to start with.

Thanks for the input.
 
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