1995 Crownline 202 BR Deck Restoration

[Badfish95]

Last Summer I got "suckered", so I named her Badfish. It's also the name of my favorite song.

She was in a darkly lit shed with a cover on. I opened the cover and was hit in the face with a musty, moldy, damp dose of Lake... Seller said his buddy borrowed it and never pulled the drain plug before covering it. There were signs of abuse in the rub rails, scuffs in the gelcoat, and trash in the hard to reach areas. But for the price, who could resist buying this piece of family fun! :faint2:

Maiden voyage: Took the boat out with some friends to enjoy the 4th of July fireworks show over the lake. Engine bumps right off, she pops up on plane with ease, and rides as smooth as silk. I am a happy camper. When we got back to the house I decided to look into the bilge. Yep, full of water. More water than ever accumulated in my 1986 Four Winns. Turns out the shift cable bellow and u joints were shot. I decided to do the work myself. ~$500.00 in parts and a weekend of labor later, the bilge is bone dry and u joints were good as new.

Even though the boat was shed stored and was not taking on water in the rear bilge area, there was always dampness in my ski locker. The anchor and rope were covered in mildew and it would not dry out even with a fan on it for a week.

Thats when I felt the soft spot under the bench seat. You know the rest of the story. This forum has helped me game plan the restoration and talk me back from the ledge. I hope my experience will help others.

Here she is before the "deck lift".

 

[jigngrub]

Re: 1995 Crownline 202 BR Deck Restoration

Nice looking boat and it's a shame she was neglected, but she'll love you forever if you fix her up.

 

[tpenfield]

Re: 1995 Crownline 202 BR Deck Restoration

Welcome to iBoats . . . looking forward to updates on your restoration project. We like lots of pictures . . .

 

[Friscoboater]

Re: 1995 Crownline 202 BR Deck Restoration

That is a nice boat. At least you have a big place to work on her.

 

[Bondo]

Re: 1995 Crownline 202 BR Deck Restoration

Thats when I felt the soft spot under the bench seat. You know the rest of the story. This forum has helped me game plan the restoration and talk me back from the ledge. I hope my experience will help others.

Ayuh,.... Welcome Aboard,.... Sounds like yer takin' the shock well,... We're here to help,...

Sharp lookin' boat,... What motor, 'n drive,..??

 

[Badfish95]

Re: 1995 Crownline 202 BR Deck Restoration

That is a nice boat. At least you have a big place to work on her.

Thanks! The boat had the three things I was looking for:

1. At least 20' in length, 20'2"
2. V8, 305 Mercruiser LX
3. Tandem Axle Trailer with brakes.

I figured with these basics, I had some bones to work with. It also has a wide beam. Although it takes up the whole lane when trailering, its nice having extra room inside.

The shed is my friend's and it is ideal for this kind of work! He's not charging me rent, helps work on it and even offers to heat it on cold days! Compared to your driveway setup, I'm building in the lap of luxury. That being said, this boat will not be getting the extreme makeover that yours did. I do not have the determination nor the budget to pull off a build like yours. Many of your techniques will be incorparated so I thank you for such a detailed build.

Here is my hull,deck,stringer philosophy and then I will get with the pics:

Flotation is good. Flotation in the hull is bad. New 2 part foam is good. Old 2 part foam is bad. Ventilation of the hull is good. No ventilation is bad. Limber holes are good. No limber holes are bad. Moisture outside the boat is good, Moisture inside the boat is bad.

Based on these truths, no foam will be going back into the hull of the boat. No 2 part foam, sheet foam or pool noodles. My theory is that any foam put in there is going to sweat. The sweat becomes moisture. Without airflow and drainage, there is no way for the sweat(moisture) to get out of the bulkheads. Fiberglass is a natural moisture barrier. I will employ limber holes with PVC 5200'd in. I am also considering vents under the bow seat storage area to let air in for better circulation. I will be using Polyester Resin! That's what it was born with. I will be reinforcing it with additional stringers. All stringers, decking and interior framing will be made of Marine Plywood(Cuz when it rots I want the best rotted wood on the lake!). All floatation added will be in the gunwhales and cap.

Interior without Bench in. Doesn't look terrible right?

I used a simple tool to tear out this part of the floor... my finger.

Here is when I thought it was only the rear of the deck that was rotted..... if iboats had a nickel...

The tank and seats are out but the rot will not stop...

The ski locker got the screwdriver test, and failed miserably.

This photo brings us up to date. I will be cutting the new stringers as I take out the old, to keep an even plane. Not all will be replaced, as many are going to receive reinforcement.

More to come........

 

[Badfish95]

Re: 1995 Crownline 202 BR Deck Restoration

Bondo asked, "Sharp lookin' boat,... What motor, 'n drive,..??

5.0 Mercrusier LX with an Alpha One Gen II outdrive, if I remember right. It has the 4 barrel carb and I think is rated around 220 Hp or so.

With the wide beam and relatively flat bottom, it jumped out of the water. Top speed wasn't much to brag about, but without all the excess water tagging along, it may improve. I believe I got 49 MPH on the GPS with it.

 

[Bondo]

Re: 1995 Crownline 202 BR Deck Restoration

Bondo asked, "Sharp lookin' boat,... What motor, 'n drive,..??

5.0 Mercrusier LX with an Alpha One Gen II outdrive, if I remember right. It has the 4 barrel carb and I think is rated around 220 Hp or so.

With the wide beam and relatively flat bottom, it jumped out of the water. Top speed wasn't much to brag about, but without all the excess water tagging along, it may improve. I believe I got 49 MPH on the GPS with it.

Ayuh,.... That's a nice decent reliable package, that up-grades to a 350 quite easily,....

 

[79Formula]

Re: 1995 Crownline 202 BR Deck Restoration

You hit 49 with water logged stringers. Loose the weight by putting in dry wood. I bet you see 52-54.

 

[Badfish95]

Re: 1995 Crownline 202 BR Deck Restoration

Ayuh,.... That's a nice decent reliable package, that up-grades to a 350 quite easily,....

Hopefully I get a few years out of the 305. When it gives up, a 350 will go in its place for sure.

 

[Badfish95]

Re: 1995 Crownline 202 BR Deck Restoration

You hit 49 with water logged stringers. Loose the weight by putting in dry wood. I bet you see 52-54.

That sounds promising. Like I stated earlier it pops out of the water well, even when loaded down with people. I ran a 19 pitch for a good mix of power and top end. The 21 was a little doggy with a full boat. With gas at $3.50+ it would be nice to be able to go with the 21 and be satisfied with overall performance. Top speed isn't my biggest priority.... especially without a floor!

 

[Badfish95]

Re: 1995 Crownline 202 BR Deck Restoration

Here's my list of materials purchased.

15 yds 1708 Biax
25 yds 1.5 oz Mat
10 Gallons Poly Resin
Extra Mek, Styrene and wax additive
Rollers, Brushes, mixing tubs
2 tubes of 3M 5200
4 gallons of Cabosil
2 large tubes of PL Premium for bedding Stingers
2" and 1.25" Stainless Steel Screws
5 3/4" 4X8 Sheets of Marine Grade
Misc.: 36 grit flap discs and various other blades for sawzall and oscillating tool. Coveralls, Respirator, rubber gloves.

With shipping charges I probably have about $1,200 in it already

My budget is/was $1,500.00 and I still need carpet.:facepalm:

Let me know if you think I'm light or heavy with any of the materials.

 

[Bomber Goober]

Re: 1995 Crownline 202 BR Deck Restoration

Here's my list of materials purchased.

15 yds 1708 Biax
25 yds 1.5 oz Mat
10 Gallons Poly Resin
Extra Mek, Styrene and wax additive
Rollers, Brushes, mixing tubs
2 tubes of 3M 5200
4 gallons of Cabosil
2 large tubes of PL Premium for bedding Stingers
2" and 1.25" Stainless Steel Screws
5 3/4" 4X8 Sheets of Marine Grade
Misc.: 36 grit flap discs and various other blades for sawzall and oscillating tool. Coveralls, Respirator, rubber gloves.

With shipping charges I probably have about $1,200 in it already

My budget is/was $1,500.00 and I still need carpet.:facepalm:

Let me know if you think I'm light or heavy with any of the materials.

as far as 1708 CSM and resin, thats about what i was figuring to do my entire 14' trihull and I ony have 2 small stringers. I was advised that i would probably need more resin. So I'd say probably light but you can always order more

 

[Badfish95]

Re: 1995 Crownline 202 BR Deck Restoration

as far as 1708 CSM and resin, thats about what i was figuring to do my entire 14' trihull and I ony have 2 small stringers. I was advised that i would probably need more resin. So I'd say probably light but you can always order more

Thanks for the reply. My plan is to only replace the worst of the stringers. The new stringers will be wrapped in 1.5 oz mat before installation. I will bed with PL and fillet them in. The layers of structural glass will be a 4" strip of 1.5oz followed by 6" strip of 1708 followed by 8" strip of 1.5 oz mat then 10" strip of 1708. The decking will get 1.5 oz mat on top and bottom. The Deck will be screwed downfilleted in and then all will be capped with a layer of 1708. Hopefully, I have enough matting, but I can see where adding additional stringers for strength will eat material quickly.

 

[StevenT]

Re: 1995 Crownline 202 BR Deck Restoration

Here's my list of materials purchased.

15 yds 1708 Biax
25 yds 1.5 oz Mat
10 Gallons Poly Resin
Extra Mek, Styrene and wax additive
Rollers, Brushes, mixing tubs
2 tubes of 3M 5200
4 gallons of Cabosil
2 large tubes of PL Premium for bedding Stingers
2" and 1.25" Stainless Steel Screws
5 3/4" 4X8 Sheets of Marine Grade
Misc.: 36 grit flap discs and various other blades for sawzall and oscillating tool. Coveralls, Respirator, rubber gloves.

With shipping charges I probably have about $1,200 in it already

My budget is/was $1,500.00 and I still need carpet.:facepalm:

Let me know if you think I'm light or heavy with any of the materials.

BF you might want to consider using Arauco plywood. All the guys on this forum who have used it stand by it. No voids and waterproof glue. You can purchase it locally from Lowes or HD. It will cut your plywood cost by about 60%. Marine or Arauco encapsulated and maintained correctly will give you decades of use.

 

[Bomber Goober]

Re: 1995 Crownline 202 BR Deck Restoration

As far as doing your stringers.I noticed WOG hasn't checked in on this one yet and not to steal his thunder, but .

This has been researched and recently revised by WOG and will be stronger and better than factory and last close to forever.(**WITH PROPER CARE**)
also some other good reading and diagrams for transoms and decking.
"Fabricating Decks, Stringers, and Transoms"

EDIT: Also if you watch Friscoboaters Youtube videos when he did the stringers on the Carlson he is working on, It was also done this way. Lots of watching to get through all his projects, but well worth it.

 

[Badfish95]

Re: 1995 Crownline 202 BR Deck Restoration

Thanks for the layup info! I have been all over this site and did not see that layup diagram. I also took StevenT's advice and traded my 5 sheets of Marine grade plywood for 6 sheets of 3/4" Exterior grade Fosterburg AC Superply and a $70.00 store credit(Not that I would need additional supplies or anything...). Its a Fir plywood with one sanded side. It looks like my areas version of Arauco, which I could not find anywhere.

So tonight I will be grinding the sides of the hull and cleaning up where bad stringers were cut out. Wish me luck!

 

[Badfish95]

Re: 1995 Crownline 202 BR Deck Restoration

MAJOR PROGRESS!!!!! Here are the photos complete with commentary:

We took the two main stringers all the way to the front of the boat, without decapping. We left a few temporary stringers in in order to keep the bow section from sagging. My dad came into town and has been a huge help. I don't think he knew what he was getting into, but he's been a good sport. The amount of dust and grinding involved can be extremely discouraging. I kept telling myself, just keep grinding, it'll all be over soon.

12 straight hours of grind, vac, clean filter, grind, vac, clean filter....

Rotted bench was used as a template for the new one. It was held together by the carpet covering it!

Starting to see a light at the end of the tunnel.

New stringers cut to fit. We included limber holes to makes sure the water gets out of the boat. I made them oversize since they will be getting PL glue and Resin coated which should close the gap a little. This should allow the whole hull to breathe, thus eliminating issues like hull blisters and a wet foam. Of course that's if I was going to re-foam the hull, which I'm not.

Test Fitting. Everything lined up almost too well. We made sure to cut everything about 1/8-1/4" undersized to avoid hard spots.

 

[Badfish95]

Re: 1995 Crownline 202 BR Deck Restoration

All Stringers received a coat of poly resin with 10% styrene mixed in to thin it out. It took a little longer to dry, but seemed to penetrate well.

Stringers are bed in! We used 5 tubes of PL Premium. I used a brad nailer to tack the stringers in while it sets. It will all be glassed over so they will be encapsulated. It was great feeling to have bones back in my boat. There were a few times during the build that I wondered if this day would ever come.

This photo brings us up to date. The PL Premium is drying currently. My dad and I have logged about 32.5 hours each in the cutting of stringers, grinding, recutting, resin coating and bedding of stringers. We took a half day off to let the glue dry and reward ourselves.

Saw this Marine grade 16 oz carpet at Lowe's for 1.28 sqft. What do youguys think? Beige(close to original), Midnight(Dark grey) or Maroon(Boat's accent color)?

 

[wolfsmurf]

Re: 1995 Crownline 202 BR Deck Restoration

U flying right thru this dood. Was wondering why your not going to use foam? I have read all the posts on yes or no foam and I'm going back with it in my little boat for more for the structural plus sides rather than the flotation benefits.