The Beginning - 1964 Starcraft 18.5ft Aluminum Rebuild
I pick up this old 1964 Starcraft Starchief from a guy in Shelton, WA. He got it from his father inlaw who had removed the old cabin. It has a matching 4cyl 110Hp Merc in good condition.
I started with the teardown on the entire boat, everything must go as the old centre consoles were very intrusive. With the help of a 1982 Glass-Ply as my parts boat I will be creating my own custom Starcraft Fishing/Sport boat.
Here are a few pics:
The rebuild will start at the hull with a polyurethane foam spray filled to the floor. I am leaving the old cabin benches up front and will be installing my captains chairs on them. The Bow will be extended by 14" to fit the controls from the parts boat, complete aluminum topside resurfacing.
The windshield will have a 6" aluminum riser in order to give me more height and give me a place for my wiper.
From here it will be all of the little things like heat, lights, downriggers/rod holders, anchor roller/mount, vents etc.....
New pics to come after the floor gets sprayed and sheeted!
Re: The Beginning - 1964 Starcraft 18.5ft Aluminum Rebuild
Looks like a fun project. But I'm partial to aluminum hull rebuilds.
"will start at the hull with a polyurethane foam spray filled to the floor"
On my Starcraft the original foam was rigid lengths that layed across the ribs. This left an air space where water can drain underneith the foam. I recommend cleanning out the dirt at the center V of each rib. There is a thin space (butter knife) under the rib to allow water to drain to the back of the boat. It doesn't take much dirt for it to form puddles.
I highly recommend a leak check. There are probably at least a couple of rivits with slow leaks. Most can be fixed by repounding the rivet. Some maybe need replacing or gluvit. I had the boat securely on the trailer, and filled it with water to the floor level. Careful, it will be allot of weight.
Good luck, it looks like a great start to a fun project.
Re: The Beginning - 1964 Starcraft 18.5ft Aluminum Rebuild
JB, will tell you it's not a floor but a DECK. also consider coating the interior with Gluvit, before the foam. it is a aluminum boats best friend. seals all those potential little leaks.
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Re: The Beginning - 1964 Starcraft 18.5ft Aluminum Rebuild
I have a '67 Starchief and I am at a similar stage of rebuild - at least as far as the deck goes. Seems a shame to lose the cuddy on that boat... but to each his own.
I ripped the plywood deck (in pretty good condition) and old foam sheets( a real mess, crumbling apart and few old mice nests in there) out last fall.
I just did the leak test by filling with water... I found 7 drips,(glad I took the time to do this!) plan to pound the rivets then apply Gluvit (bought it, now waiting for a day above 50 degrees to do it.
Also ordered 2 part foam from US Composite - will need to wait for a much warmer day before pouring that.
Glad to see I'm not alone.. good luck with your project.
Re: The Beginning - 1964 Starcraft 18.5ft Aluminum Rebuild
I was going to do a water check this week, but doesn't the polyurethane foam seal up the hull anyways? There should be no space for water to go past the "leak point" in a sense creating a solid core hull. Also what is gluvit? Is it a type of cauking?
Re: The Beginning - 1964 Starcraft 18.5ft Aluminum Rebuild
I don't believe the foam will stop any water from entering the boat, it is just there for flotation in the event you get swamped. Gluvit is a 2 part epoxy designed for marine use to seal leaks. This will be my first time using it, but I've read enough good things about it to justify the $45.00 I paid for a quart of it.
They sell it here on iboats, here some info from the iboats page:
Gluvit barrier coat seals and protects hulls and decks. Provides superior protection for fiberglass, wood, aluminum, and steel. Seals leaky seams and rivets in aluminum hulls, and leaks around fiberglass cabins or decks. Hard protective coating flexes with hull movements to bridge and seal hairline cracks.
Gluvit fills minor cracks and pinholes. Its long working time allows penetration into cracks to seal and strengthen. Acts as a barrier coat to minimize water absorption and galvanic corrosion. Deteriorated wood can be renewed with a few strokes to penetrate and strengthen stringers, decking and molding.
Re: The Beginning - 1964 Starcraft 18.5ft Aluminum Rebuild
Rebuild update......
Taking some good advice I went out and picked up 2 quarts of Gluvit, cleaned and sealed every rivet on that boat, all of the major seams also recieved a second coat.
I just got back tonigh from having the boat foamed with polyurethane spray foam, man does that ever tighten things up. Hopefully this weekend I can get the floor in and the top resurfaced (new aluminum).
The farther I get into the project the more excited I get to take it out on the water! Especially seeing as how the summer is just around the corner and we've been getting some decent weather up here lately!
The trailer has recieved 4 new bunks, 2 12ft mains and 2 6ft side runners along with 2 6ft guide bunks all mounted on new mounts (originally the boat sat on 2 bunks ON THE CHINES that only had 4 mounts total) now the boat sits on 10 mounts!
The top has been resurfaced with all new aluminum, cut to size and riveted on top to help beef up the structure, and look. The original bow had the port hole in the top witch has now been covered over and the bow extended back a foot, the windshield has recieved a special riser mount to raise the height of the windshield and angle it up more.
As far as the interior goes, the floor has been completely layed with new 5/8" ply, new doghouse, the dash(s) have been built and are now awaiting a cover of vinyl and aluminum.
Now it comes down to re-wiring the ignition system, completing the siding, bench seats, captains chairs and the new top. All in good time.....
Re: The Beginning - 1964 Starcraft 18.5ft Aluminum Rebuild
Do you have any more pictures of the engine cover construction? I need to build one almost identical to that for my 22 ft. Starcraft and I was curious as to how you braced the inside of it and screwed it all together.
Re: The Beginning - 1964 Starcraft 18.5ft Aluminum Rebuild
That's a good build.
If you need some pictures, I have them of an original Starchief that was my Great Grandfathers. I just got back from Canada and have some pictures of it. If anyone know of someone looking for one of these Starchiefs in Great condition, we have decided to sell it so we can fit another boat in the boathouse! It was used at least once a year since 1965 up until 8 years ago when my great uncle passed away and my aunt didn't use it. I drained the old gas out of it and put new in, put new lower unit oil in and it started right up. Didn't miss a beat! Don't know what it's worth, but I'll post pics of the engine compartment for the other guy. Thanks
The Beginning - 1964 Starcraft 18.5ft Aluminum Rebuild
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