1987 V20 CC-SD Cap Off Restoration

[cbe317]

OK Guys, *time to get 'r dun. ;)

Let the destruction begin.

Here it goes.....


I started yesterday pulling the skin off the inside of the transon core. *The transom had more rot than I expected:

http://i82.photobucket.com/albums/j254/cbe317/Boatteardown017.jpg

Any of you full transom or I/O guys should really check your transom. *It seems to me that with the three piece core like this, water intrusion is inevitable.

Here are some close-ups:

Port
http://i82.photobucket.com/albums/j254/cbe317/Boatteardown019.jpg

Starboard
http://i82.photobucket.com/albums/j254/cbe317/Boatteardown018.jpg

I also found the stringers to be very wet. *The boat hasn't been in the water in 6 months. *But, by the look of it you'd think it just came out yesterday.

Stringers:

http://i82.photobucket.com/albums/j254/cbe317/Boatteardown021.jpg
Notice the nice round hole in the core. *That was my finger. *The wood has become SOUP!

http://i82.photobucket.com/albums/j254/cbe317/Boatteardown020.jpg

Talk about STINKY!!!! :o
I have never smelled anything quite as putrid as this:
http://i82.photobucket.com/albums/j254/cbe317/stinky.jpg


Here is a shot of the tank tag:
http://i82.photobucket.com/albums/j254/cbe317/Boatteardown012.jpg

The company is still around, but they are not called AFP anymore. *They are now called *RDS Manufacturing.
Here is the link: *http://www.rdsaluminum.com/homepage.html

Check the story and truck box catalog out here:
http://www.rdsaluminum.com/images/05CATALO.PDF

Anyways, *I will be updating every once in a while. *I will be pretty busy with work this summer. *So, most of this will be done on weekends and nights. *

Now, Back to cutting/grinding. *Man it's HOT today! :P


Chris

[tsubaki]

Man that's way more than I would want to do at once but it don't look like you had any choice.
Just doing my transom made me question if I was an alcoholic. ;D ;D

[macojoe]

That sure needed to be fixed!! I am not looking at mine, I don't want to know!!

I do know this, I can bounce my motor up and down on the transom with tyhe bracket and see or hear anything, and thats ok by me!

Good luck! And keep us posted!

[bradford]

While you're tearing stuff up check your fuel tank. the one in my 85 had a couple of fist sized holes from corrosion caused by the foam holding so much water.

[reelapeelin]

Big job, cbe, but it'll be worth it when finished ;) ...thanks for the pix 8)...glad no scratch n' sniff :P ... at this point, it seems pullin' the tank would be a good idea ... you gonna remove all stringer material, or leave glass and fill voids?...

[Stillrunning]

Did you take the inner skin out or cut it away? If you took it apart did you take any pics? Looks like you have your work cut out for you.

[cbe317]

Did you take the inner skin out or cut it away? If you took it apart did you take any pics? Looks like you have your work cut out for you.


Which inner skin are you referring to? *If you are talking about the transom inner skin, *this is the pic I took after cutting the perimeter with a grinder. *
http://i82.photobucket.com/albums/j254/cbe317/Boatteardown017.jpg
I then took a flat bar and pried the skin loose from the core. *It came right off where the wood was rotten. *Where there was still good wood I had to beat the bar in with a hammer, but it would still pop off pretty easy. *If you look closely you can see thie skin sections I cut out on the ground behind the ladder.
I am in the process now of removing all the old core(plywood) from the transom. :P




I do think I will pull the tank out. *I have pressure tested it, and it tests good. *But, I think with all the extra room there is forward of the tank,
http://i82.photobucket.com/albums/j254/cbe317/tankview.jpg
I might look into putting a 100gal tank in there. ;D

Reel, I haven't decided yet on what to do about the stringers. I will have to see how far up the water goes. I am gonna do the transom first, and then work my way forward.




Chris

[mauryc]

How bad was removal of the top cap? Got any pics of that?

Maury

[macojoe]

Deal with the stringers at the same time!! This way when you do the transom, you cann add knee boards and glass all toghter fore xtra support.

[cbe317]

Flounder,

The cap really just pops off. I didn't take any pic of that process. It's pretty simple though. I made a lift out of 6x6 and double 2x10 cross-beam.
http://i82.photobucket.com/albums/j254/cbe317/Boatteardown016.jpg
I used two 880lb electric hoists I picked up at harbor freight. Make sure you lift from the floor hatches and not from the gunwale sides. The cap will flex too much upon lifting. I just used a 4x4 as a lifting block catching the sides of the back-most hatch and the forward hatch. The 4x4 catches the deck on either side of the hatches for better lifting without flex. There is a grout material that was used for leveling the deck on the stringers and bulkheads. It took a little persuasion but it just popped loose eventually.

MJ, I just mean doing the deconsruction phase of the transom first. Then I will move forward with the chaos. I will certainly tie the knees into the transom when I redo the stringers.

Here is the transom with all the core pulled out. The wood you see is just a small layer that needs to be sanded off.
http://i82.photobucket.com/albums/j254/cbe317/Boatteardown022.jpg
I should have all that sanded out tomorrow.


Chris

[macojoe]

Ok I gotcha! Good work there!!

when you are done Come on over to my place!! I have pleanty of work for ya! ;)

[phatdaddy]

CBE, looks like your gonna have a fun summer. on your cap shot, i noticed the gap in the stern between the side compartments. did you cut the corners of the cap off where they attached to the transom?

[cbe317]

CBE, *looks like your gonna have a fun summer. *on your cap shot, i noticed the gap in the stern between the side compartments. did you cut the corners of the cap off where they attached to the transom?

If you mean the large cutout in the stern, then no. The center consoles that came from Wellcraft with a full transon use a molded removable insert there. You can see it leaning up against the post just next to the cap. Essentially, this boat is a I/O hull with a special cap. The cap is unlike most CC's which, IIRC, do not have the "battery" compartments on the corners of the back end of the deck. But they do have the flip up hatches on the transom.
http://i82.photobucket.com/albums/j254/cbe317/Boatteardown016.jpg

This is the insert when it was still installed:
http://i82.photobucket.com/albums/j254/cbe317/7a75f56a.jpg
I did not have to cut anything to get the cap off.

Just remove about 200 screws and lift. ;)


Chris

[tsubaki]

cbe, you already got good locations to buy resin, hardware, etc, etc?

[cbe317]

cbe, you already got good locations to buy resin, hardware, etc, etc?

Tsu,

I am going to use MAS epoxies on this project. I will order that and all the cloth online from:
http://www.jamestowndistributors.com/userportal/search.do?freeText=mas%20epoxies&page=GRID&history =

I get all my hardware and other stuff from River Supply here in Thunderbolt.


Chris

[tsubaki]

Good,I was going to suggest them. Most of their stuff is great and good to cheap prices.
Before I started on mine I had no idea how limited the supplies in this area are till I just walked in there.
Good luck, Benny

[Stillrunning]

I found the same when taking my V20 apart that it does just kind of pop out. I used a pulley in a tree with all ropes meeting just over where the CC was. I then use a car to hoist it out. The only problem I had was when we had the inner shell about a foot or two up we heard a crack and the limb we used gave way. The good news was when it broke it stayed attached to the tree and did not fall on the boat. While you have the inner shell out i would give the flooring a good inspection as it would be easy to replace the wood while its apart.

[cbe317]

WOW! Getting the rest of that wood out proved to be a task.

It took three days to get from this:
http://i82.photobucket.com/albums/j254/cbe317/Boatteardown022.jpg

To this:
http://i82.photobucket.com/albums/j254/cbe317/Boatteardown024.jpg

http://i82.photobucket.com/albums/j254/cbe317/Boatteardown025.jpg



I will be grinding the rest of the edges down next. Then I will start moving forward with the madness. ;)

Why am I all ithchy ?? ;D


Chris

[tsubaki]

Oh Man, that looks virgin.
Sorry can't help myself.
So (I already asked) you going bracket or what?

[cbe317]

Oh yeah. It will be bracketized! I have yet to find one though. I want a 30" setback without the swim platform. Unless I can find one with a platform that matches the curve of the transom. I have only seen one like that so far. The guy was asking $1200 used. :o

I already have a '94 Merc 200 2.5l offshore. The last of the good ole 2.5's. Weighs only 365lbs. It is a factory NEW powerhead with carbs and intake from a 225.


Chris

[THEFERMANATOR]

Why is your 2.5 so light? My 95 2.5 150 XRi(EFI) is listed at 410 lbs, and that is a 20" shaft engine.

[cbe317]

That's a good question. I put it on the scales in the crate that it came to me in, and it weighed in at 418lbs. The crate is a factory yamahe crate. It is made out of a thin steel frame with a thick steel mounting bar. I figured the crate probably weighs 50lbs.

I just went and looked at the sticker and it's a 93. Duh. All this time I thought it was a 94. I pretty sure this was the last of the "old style" mercs.
Here it is:

http://i82.photobucket.com/albums/j254/cbe317/Boatteardown028.jpg

[tsubaki]

Good going. MJ will be praiseing you.
There were a couple of threads that had some bracket stuff. I'll try to recall them.
Hopefully a couple of the guys that did do bracket will give their $.02.

[tsubaki]

Incase you haven't seen this.
http://www.wellcraftv20.com/cgi-bin/yabb/YaBB.cgi?board=Modifications;action=display;num=11 73654195;start=0#0
2ndchance might be able to direct you to a bracket.