Terry ABF floor repair/rebuild

[D.spencer]

Hi all- I have started my repair/ rebuild project of my Terry abf bass boat. I have been following a lot of the threads here gleaning as much info as possible. It all started innocently enough as a small soft spot in the floor and of course is now a huge undertaking I almost wish I had not started it -mainly because of the time required to do a extremely good job seems to be something I am so short of and now of course, fishing season is right on top of me . I have decided not to take extreme short cuts but on the other hand I don't think this is a rare gem worthy of complete dissassembly like some of the other boats here receive. After examing it( which has had me scratching my head- this thing is put together like a unitized body car-yet another reason for not completely taking it apart) it seems like it is possible to repair this thing rather than a full blown resto. I will post some before pics and as it is now but one question is perplexing me. Is the foam on these terry boats crucial to floor strength? I am seriously considering not putting it back in.

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

hopefully here goes before pics-

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

some more-

 

[jonesg]

Re: Terry ABF floor repair/rebuild

A lot of time is lost agonizing over whether to do it or not, the actual doing goes quicker. If the foam is bonded to the hull and there aren't a lot of cross formers then the foam is probably structural.

My 20' center console only has 2 stringers and 1 cross former in the rear half of the hull, so I think my foam is structural.

On my first launch I err...forgot the drain plug, the boat would have sank if not for the foam. Just another reason. I personally prefer wet foam to no foam. But if I was replacing it I'd find a way to eliminate a lot of it whilst retaining floatation , insert soda bottles or whatever into the new foam and create drains under it by inserting half tubes of pvc pipe or standoffs.

It always seems to start with a little soft spot or a crack in the splashwell, have you checked the transom? I mean really check by drilling holes?

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

Not by that method of drilling holes. I did remove the outboard and inspected the bolt holes where it fastened on and it seems ok. I tried sticking my pocket screwdriver in it ( all four holes in the transom wood) and although it does seem a bit damp, it was not rotten. I mentioned the being put together like a unitized body car because after examining it, I came to the realization that the factory had a LOT of people on hand when they put it together . My concern was being able to restore that rigidity by how they assembled it which was very well. I will take some pics of how it is now and try to get them posted tomorrow eve.

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

Ack- more setbacks- transom is rotten after all some more pics-

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

more pics-

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

Still more pics- The last two are a drywall tool I found extremely useful for removing the cap since it was glass taped as well as pop rivited on and it would have been near impossible to get a cut off wheel up inside the flanged area. I sharpened the chisel end, inserted under the lip and used a hammer to hit the end where the blade is attached to the bent piece using it like a chisel but with the added benefit of being able to hold the wooden handle and exert a great amount of control while breaking the bond. If it got stuck- I simply hit the bent piece on the other side to remove it . it works a lot better than I am describing here.

 

[Bob_VT]

Re: Terry ABF floor repair/rebuild

You are making great progess! Great idea for the cap removal .... you can bet I will be sending people to see that in the future.

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

More progress I removed the rear casting deck and tore out the rest of the floor. Is it normal for floor thickness to be 9/16 " ??I measured this carefully and on several different pieces of wood to make shure.

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

even more pics. I may have gotten them out of order.

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

yet more..

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

more ...

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

yep out of order these pics are-stupid computer....

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

scroll from bottom up to see the right progress- so sorry.

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

Gads- I am exhausted!! been grinding nearly **all day** today and yesterday. Even with the tyvek suit, glasses,etc and dusting off with compressed air prior to removing suit, I am itchy.... still. Talk about sweating!! I think I may be able to go down one suit size except the durn thing is kinda short as it is . I am contemplating going commando in it tommorrow just to get an adge on the heat. I made my list for US composites and then had to keep scaling it back as my order was going to big a big chunka $$$$.( still not small- just more affordable) Hopefully what I need to get started will be here next week. All the old stringers are out, most of the grinding is done except the hard to get to stuff. From what I have been reading on other threads, should the new wood be sealed with polyurethane prior to glassing it in? or just left bare so resin can "bite" it better. Would this be an advantage or too much overthinking?

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

Pics..

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

more pics

 

[proshadetree]

Re: Terry ABF floor repair/rebuild

Good progress .Youll be proud as punch when you get her back in the water.

 

[D.spencer]

Re: Terry ABF floor repair/rebuild

update to progress