Formula 330SS Bulkhead Replacement

[tpenfield]

Hi Folks:

I have been 'monitoring' high levels of moisture in the main bulkhead of my Formula 330SS over the past year, as documented in this thread that I started at the time >>> Link: http://forums.iboats.com/boat-restor...ds-584200.html

Despite my efforts, the moisture levels have not come down all that much, since the boat is stored outside over the winter months. So I decided to remove and replace the bulkhead. This is a project, that I would have been hard-pressed to do last year, since the boat was 'new-to-me'. Having familiarized myself with the boat's structure over the past year, I felt that I could now take this on, and seeing as the moisture levels remain fairly high, it is probably best to replace the bulkhead, rather than let the problem fester.

Using what I call my 1990's CAD system, I was able to make an illustration of the boat's hull & structure. Using these drawings, I have planned out the process.

Here is the hull of my boat. . . the main bulkhead is in Blue and the stringers are in green.



The area of high moisture (and presumably the source of the problem), is the orange hashed area.

I plan to cut out the center section of this bulkhead out to the point where it meets the main stringers that surround the fuel tank.



This will expose the rear portion of the fuel bay, where I plan to remove/replace some of the foam that holds the fuel tank, to provide a working area. This will also let me inspect the rear face of the tank, etc.



There is a cross member (yellow) that I plan to leave in place. Then, I will fabricate a new section of bulkhead and replace it.



So, that's "the plan" . . .

Yesterday (Sunday) was 'cutting day'. I figured that I would cut out the bulkhead before winter really sets in and let it sit over the winter, finishing it off in the spring (like April/May).

* * * continued on the next post * * *

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

I started out the day by adding some support to the hull below the work area. . .



There are all kinds of electrical wiring, plumbing and fuel lines that run across and over this bulkhead. Removing all of this stuff would be seemingly impossible. . . So my plan was to detach everything from the bulkhead and work around things as much as possible. I also did some measuring and drilled a couple of 'starter holes for making my cuts with the sawz-all. (below)



I removed the top section of the bulkhead to 'open' things up a bit and provide access to cut the bulkhead from the 'spacer/stiffener' that runs across the fuel tank bay. Then I cut out the lower section of the bulkhead in 2 pieces (port & starboard)

I still need to cut out some material from around the engine mount stringer, but I was loosing daylight at that point, so decided to call it a day.

Taking a page out of 'Goldie627's book (he is rebuilding his 86 SeaRay), I made a couple of videos as well. Sort of brings the project to life. The sound is a bit low (sorry) but here they are:

Part 1 - Planning: http://www.youtube.com/watch?v=bXLkQo_TRxs

Part 2: - Cutting: http://www.youtube.com/watch?v=3dXMNJ5j2gY

It seemed that the real problem was that the back side of the bulkhead was not fully glassed/resin leaving bare wood to absorb moisture from the fuel bay. So, it is good that I am replacing it.

I need to clean up the cut lines a bit and do some more work on cutting around the center engine mount stringer that butts up to the bulkhead. Then I'll let things sit over the winter.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

I have been thinking about the two 'discoveries' that I made while cutting out the bulkhead on Sunday.

(1) Bare wood on the hidden side of the bulkhead . . . and . . . (2) the void in the foam on the port side, up against the bulkhead.

These 2 issues seemed to have worked in combination resulting in the 'wet' bulkhead after 15+ years of the boat's life.

I figure that the moisture that collected in the foam would tend to condense on the surface of the void area, and then have a downhill path to the exposed wood surface of the bulkhead as pictured below.



You can also see a glimpse of the fuel tank in this picture (gray triangular shapes). So, it will also be interesting to see if moisture was trapped up against the tank surface.

So, it looks like a combination of issues can lead to problems after 10-15 years of a boat's life cycle. If the foam did not have a void . . . or . . .if the bulkhead had been fully glassed, then the moisture problem may not have happened at all. . . or be much more minimal.

 

[Scott Danforth]

Re: Formula 330SS Bulkhead Replacement

Good work so far Ted. hope the moisture is only contained within the buklhead.

if it is just contained within the bulkhead, you should be done in no time. However based on working in my bilge almost 2 years ago, you will need to move most of the plumbing and wiring out of your way to make things easier for you. It may seam like a daunting task, however painters tape and a sharpie work well to label the wiring.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Thanks, Scott. I am thinking that some of the moisture has made it into the stringers, based on the moisture meter readings that I did last year. Once I get some of the foam out from the rear of the tank, I'll have a bit of access to the main stringers for inspection.

i will probably have to disconnect some stuff that leads into the fuel bay in order to get the new bulkhead piece in place. So, I'll take your advice on disconnecting stuff and getting it out of the way. Some of the wiring . . . God only knows where it begins and ends

 

[Woodonglass]

Re: Formula 330SS Bulkhead Replacement

Hope for the BEST, Plan for the WORST!!!!

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Hope for the BEST, Plan for the WORST!!!!

Yup, "BEST" would be good, but I know things will probably come in somewhere between the extremes. I am thinking back to last year, when I purchased the boat and the value of a good surveyor. . . he gave me the heads up on the issue, . . . I think a less detailed surveyor may have missed it.

Having been down this road with my previous boat, (F-242SS), I feel so much better getting at things in a much earlier stage of progression. I would have to say my 242 was more the "WORST" scenario.

 

[zool]

Re: Formula 330SS Bulkhead Replacement

It seemed that the real problem was that the back side of the bulkhead was not fully glassed/resin leaving bare wood to absorb moisture from the fuel bay. So, it is good that I am replacing it.

Thats the exact same area mine was turning dark....the are of the bulkhead just aft of the tank...it appears they set the tank 1st, then the aft bulkhead, which doesnt allow glassing to the hull on the tank side...I left gaps in the joints and filled with lots of pb ...there were a few small areas on the stringers, but only where the factory didnt cap with glass, on the stepdowns. Most of the stringer material I removed was blond wood.

There was also a small area of rot in the transom, but only where aftermarket holes were drilled for transducer/speedo wires to come thru..the rest of it was good.

What Im saying is, your setup is similar to mine, and I would guess you'll be on the "less extreme" end of the spectrum...mine wasnt exactly stored in optimal conditions...and spent ALOT of years uncovered.

 

[alldodge]

Re: Formula 330SS Bulkhead Replacement

Wish I would have noticed your first post but is your water tank leaking? Mine was, had several pinholes develop through the aluminum tank. Got into the aft cabin and cut the tank out and reinstalled a new one.

 

[Scott Danforth]

Re: Formula 330SS Bulkhead Replacement

. . . God only knows where it begins and ends

It begins at the bow and ends at the stern...there are a bunch of connections near the helm.

LOL

in all seriousness, you should be able to unplug the motors, disconnect the batteries, transom light, blowers, and peal the whole harness out of your way, maybe even tie it up to the gunwale out of your way.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Thats the exact same area mine was turning dark....the are of the bulkhead just aft of the tank...it appears they set the tank 1st, then the aft bulkhead, which doesnt allow glassing to the hull on the tank side...I left gaps in the joints and filled with lots of pb ...there were a few small areas on the stringers, but only where the factory didnt cap with glass, on the stepdowns. Most of the stringer material I removed was blond wood.

There was also a small area of rot in the transom, but only where aftermarket holes were drilled for transducer/speedo wires to come thru..the rest of it was good.

What I'm saying is, your setup is similar to mine, and I would guess you'll be on the "less extreme" end of the spectrum...mine wasnt exactly stored in optimal conditions...and spent A LOT of years uncovered.

Yes, blond wood would be good (hey that rhymes ). IIRC, it looked like on your boat, that the tank may have needed to go in first, then the bulkhead. The bulkhead on my boat was tabbed in on both sides, but it looked like they neglected to run the resin roller up any higher. On my previous boat, that had more severe problems, the bulkhead wood was black as charcoal and it had infected the stringers.

My test holes on the outer engine mount stringers showed 'blond' wood, but there is a set of main stringers inboard of those that are closer to the source of the moisture. I am optimistic about those, since the bulkhead wood itself still had some lightness of color to it. I am thinking that I may want to give the exposed edges a shot of 'penicillin' just to fight off any rot that may become active once things are sealed up. I am thinking about either Bleach or Ethylene Glycol :noidea: . . . .

I 'doped' up the center engine mount stringer with EG last spring, since the moisture levels there were fairly high. The stringer itself is about 4" wide, but more like a box structure rather than solid pieces of wood laminated together. It will be 'interesting' to look inside of it, once I get it fully separated from the bulkhead. I have one of those Ryobi Inspection Cameras (i.e. borescope) ready for the task.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Wish I would have noticed your first post but is your water tank leaking? Mine was, had several pinholes develop through the aluminum tank. Got into the aft cabin and cut the tank out and reinstalled a new one.

Do you mean the water heater tank ? . . . It is on the port side, just in front of the batteries. The 'fresh water' tank is in the bow, beneath the anchor locker . . . then there is the 'black water' (waste) tank that is suspended over the fuel tank.

Not sure how that compares to the Formula PC's layout. The water heater tank *might* be leaking, since it is 17 years old. I did some pressure testing on the cooling system during winterization (closed cooling that runs to the water heater), but I did not really 'hear'/see any leak.

 

[alldodge]

Re: Formula 330SS Bulkhead Replacement

Do you mean the water heater tank ? . . . It is on the port side, just in front of the batteries. The 'fresh water' tank is in the bow, beneath the anchor locker . . . then there is the 'black water' (waste) tank that is suspended over the fuel tank.

Not sure how that compares to the Formula PC's layout. The water heater tank *might* be leaking, since it is 17 years old. I did some pressure testing on the cooling system during winterization (closed cooling that runs to the water heater), but I did not really 'hear'/see any leak.

In the PC the hot water tank is port side in front of batteries as the 330, the water tank is on the port side of the fuel tank under the aft cabin. The waste tank is on the starboard side in the engine compartment. If you have an aluminum water tank it may have pin holes in it, mine and many others have had the same issue with aluminum water tanks.

I say this only from a quick read on both your post.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

It begins at the bow and ends at the stern...there are a bunch of connections near the helm.

LOL

in all seriousness, you should be able to unplug the motors, disconnect the batteries, transom light, blowers, and peal the whole harness out of your way, maybe even tie it up to the gunwale out of your way.

:thumb: Actually the harnesses that go to the engines route to and along the transom. Most of the wiring along the bulkhead is the 'house wiring' . . . that's the tricky part as it goes 'everywhere'. I'd like to get it out of the way, but it may run to places I cannot reach once I want to put it all back. I have to take a closer look, since I am a bit curious about it.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

In the PC the hot water tank is port side in front of batteries as the 330, the water tank is on the port side of the fuel tank under the aft cabin. The waste tank is on the starboard side in the engine compartment. If you have an aluminum water tank it may have pin holes in it, mine and many others have had the same issue with aluminum water tanks.

I say this only from a quick read on both your post.

Yea, the 'water' tank is in the bow and it is made of plastic. So, that is probably the major difference between the SS and the PC models.

I had some problems with its location since it is in a 'pocket' with no way for water to drain (see pic below). When I bought the boat, the surveyor noted that the forward bulkhead was 'wet'. Sure enough, I found that the water tank was actually sitting in water as held in by the bulkhead. The anchor locker above it had a hole in it and rain water had leaked in.

So, I emailed my good friends at Formula Tech Support and asked if there was supposed to be a drain there . . . nope.

Fortunately, this bulkhead dried out nicely in a few months time. I got a moisture reading of about 12% after it had dried out.

 

[alldodge]

Re: Formula 330SS Bulkhead Replacement

Yea, the 'water' tank is in the bow and it is made of plastic.

So, I emailed my good friends at Formula Tech Support and asked if there was supposed to be a drain there . . . nope.

Glad you have a plastic tank, at least you shouldn't have an issue there.

I like Formula tech support also but don't take all there words as gospel. I needed to replace my steering cable and asked them what the name and part number was. Bought it and it wouldn't work. Called them back and they said we sure are sorry we gave you the wrong part number. The number they gave me was for the newer helm setup and not the 94 model. To make it worst it wouldn't work with the helm they were currently using. There words to me after that was maybe you can sell it on ebay. In the end I had to buy a complete helm and another cable.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

Glad you have a plastic tank, at least you shouldn't have an issue there.

I like Formula tech support also but don't take all there words as gospel. I needed to replace my steering cable and asked them what the name and part number was. Bought it and it wouldn't work. Called them back and they said we sure are sorry we gave you the wrong part number. The number they gave me was for the newer helm setup and not the 94 model. To make it worst it wouldn't work with the helm they were currently using. There words to me after that was maybe you can sell it on ebay. In the end I had to buy a complete helm and another cable.

Yea, I have only touched base with the Formula Tech Support folks on technical advice and some materials, nothing part number-wise. Their words of wisdom helped me resolve a conflict of thoughts regarding fuel tank installation - 'foam' versus 'no-foam'.

I am surprised that they did not put you through a dealer for 'part number' ordering. For 'part number-ed' stuff, I usually just see what is there and try to get the same thing.

 

[Brian 26]

Re: Formula 330SS Bulkhead Replacement

I just read this thread, the linked one and both of your formula websites. Good stuff, thanks for posting, looking forward to seeing the progress.

 

[tpenfield]

Re: Formula 330SS Bulkhead Replacement

I just read this thread, the linked one and both of your formula websites. Good stuff, thanks for posting, looking forward to seeing the progress.

Thanks, Brian. I am looking at my weekends ahead of me . . . should I work on the boat . . . or . . . do my holiday shopping :noidea:

 

[Brian 26]

Re: Formula 330SS Bulkhead Replacement

Easy, do your holiday shopping first - for me this takes 5 minutes, go on ebay order a new stereo for our boat and give it to my wife as a gift. Then work on your boat - for me that will be rebuilding the carb in a jet ski! HA!

Actually it's not as selfish as a gift as I make it sound. She saw a boat with a swim deck stereo control and couldn't stop talking about, plus I just bought her an Iphone 5s. So I ordered Clarion's system that has the remote that integrates with the Iphone. Should be a winner, although now I have to drill a 3" hole in my rear deck.