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1987 Searay Seville Cuddy Restoration - stringer and engine mounts

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  • 1987 Searay Seville Cuddy Restoration - stringer and engine mounts

    Hello

    I've been reading a lot of posts on the forum so I think it's now good time to start our own.

    a bit of background on this new thread: we purchased the boat in oct 2016 with the trailer and 2 engines (one V6 and one V8). The look was fairly good, the hull looks sound and the trailer looks solid so we decided to give it a try altough we had little knowledge about boats in general.

    Click image for larger version

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    The boat was equipped with a Merc 4.3 V6 which was out of order (ruined crank) and a spare Merc 5.7 V8 that the previous owner purchased as a replacement but never installed.
    The V8 was seized from improper storage but looked ok, we will later discover that it was not...

    So far we focussed on rebuilding the engine, it tooks us a bit of time but it's now running fine and waiting for its installation into the hull (I'll try to cover the 5.7 rebuild into one other post). That's what brings me to this thread.

    While looking on the boat how to adapt/install new engine mounts, we found rotted wood (how strange !) so we are now looking at rebuilding the boat itself.

    Bare with me if the post/picture format is not optimal yet, I'm new to this too.

    rotted wood pics and questions to come soon
    1987 Sea Ray Seville Cuddy Cabin - 5.7 mag Mercruiser alpha one Gen I
    under restoration
    Complete HD pictures set here

  • #2
    . . . to the dry dock.

    We have a few boat rebuilds finishing up, so there is plenty of 'space' for the next few to come along Lots of threads to read through, which I'm sure you have done or are doing. Looking forward to the pictures and tagging along.
    Best regards, Ted . . . . Cape Cod, MA

    Current Boats: Formula 330 Sun Sport, O'Day Mariner Sail #3224, Sunfish
    Past Boats: Catalina 22 Sail #10531, Formula 242 Sun Sport
    Twin Mercruiser 7.4 LX MPI (0F802036, 039), Bravo 3's (0F806198, 199), Mercury 7.5 HP (1969), Johnson 4.5 HP (1980)

    My Boating Web Pages: http://www.tpenfield.com

    Comment


    • #3
      a few more general pics of the boat

      Click image for larger version

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      Attached Files
      1987 Sea Ray Seville Cuddy Cabin - 5.7 mag Mercruiser alpha one Gen I
      under restoration
      Complete HD pictures set here

      Comment


      • #4
        Good looking boat. I had moral support. A buddy did a 1966 Chriscraft and he assures me it is well worth the time and effort.

        I was told my engine needed work when I got it. Turned out the engine is fine it was the boat that needed it.
        Dance with the waves,
        move with the sea.
        Let the rhythm of the water
        set your soul free.

        1987 Four Winns 170 Horizon.

        Comment


        • #5
          Ok on to the rotten wood:

          this is the bilge area when we picked up the boat:

          Click image for larger version

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          about 3" of water sitting in there. It may have alert us but ... it doesn't

          We drained it, degreased it and hot pressure washed all the gunk
          We removed the fuel tanks to get in cleaned from the old fuel too and started to investigate on how to move the engine mount fwd for the new engine.
          that's when we discovered the soft spots in the corner between the stringer and the transom.

          after a few digging behind the fiberglass it was clear that the stringer were shot

          Click image for larger version

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          we also removed a small section of the deck to have a better view of the damage, here is how it looks like with the wood removed

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          and a view from the top

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          What you can see left from the original stringers is only fiberglass. the plywood is completely gone but it appears that it was very thin, maybe 1/4".

          what is also strange is that the inner glassing is not joining the hull all the way as you can see some foam on the rear bottom corner, and this is the same on the other side.
          however the fiberglass does a kind of step before joining the deck level where it extends maybe 10" over the foam and the stops. there was another piece of plywood (about 1" thick) in the step, some kind of clatter I believe.

          I cannot understand how they build that in factory, how can it be glassed to the deck and to the stringer/hull at the same time? there is no access once the deck is on. or maybe they build the deck and stringer as one piece upside down, glassed and then glue it to the hull and only after glassed the outer side of the stringer to the hull?

          anyway, our plan is to do a quick fix for the end of the boating season and be able to install the engine and run the boat this summer. (or what is left of it). Once the season is over, we will remove the engine again and replace the stringer / deck and transom properly.

          here is a last view of the partial demolition work after we left: V6 mounts are removed as well as the original L4 mount and the fuel tank bulkhead
          Click image for larger version

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          Oh did I mention that the wiring is also a mess ?

          did someone already performed this kind of quick fix? any advices?
          Last edited by Broaters; August 3rd, 2017, 01:18 AM.
          1987 Sea Ray Seville Cuddy Cabin - 5.7 mag Mercruiser alpha one Gen I
          under restoration
          Complete HD pictures set here

          Comment


          • #6
            If you take anyone out on the boat make sure you don't like them. Beef up your insurance too. Looks like alot of structural problems that may hurt someone. Other than that Cool project boat.
            Most times I'm wrong, Most times I stand corrected..But...Sometimes I'm right.
            1983 SportCraft Deep V OSFF 222 Cuddy Rehab
            https://forums.iboats.com/forum/boat-...ddy-walkaround
            https://forums.iboats.com/forum/engin...-new-fuel-pump
            www.flotationfoamsolutions.com

            Comment


            • #7
              Hello everyone,

              After discovering the rot last summer, we decided to go for a full rebuild rather than a quick fix on this. by lack of time and because we still had to complete the engine rebuild, the hull was leftover for about 3 weeks from now

              we finally managed to resume the work on the Searay.
              The boat is now located in a friend garage and we are able to work more freely.

              So far we have removed the transom which was more than half way rotted:

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              black and mushy wood all around.

              I'll keep posting images later on today.
              Last edited by Broaters; March 8th, 2018, 07:03 AM.
              1987 Sea Ray Seville Cuddy Cabin - 5.7 mag Mercruiser alpha one Gen I
              under restoration
              Complete HD pictures set here

              Comment


              • #8
                At least you'll know following the guidance from so many great folks on this site, you should end up with a finished boat much better than factory.
                - Eric

                Somers, WI

                Old enough to know better - but crazy enough to try anyway

                Comment


                • #9
                  ok we finished opening up the fiber on the transom : the sides are shot too Click image for larger version

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ID:	10544677 the only good point is that is was quite easy to remove :-)
                  Sea Ray factory used a lot of steel nails to glue the different plywood sheets together so it makes the removal a bit more time consuming. It also shot my new wood chisel .

                  here is how it looks with all the transom wood removed:
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                  we also removed the rear part of the deck. plywood was dead but the foam is surpisingly dry.

                  We did some investigation on the stringers:
                  the stbd one is ok from a couple of inches ahead of the engine bay
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                  the port one is damaged up to the front of the fuel tank compartment

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                  more to come soon
                  1987 Sea Ray Seville Cuddy Cabin - 5.7 mag Mercruiser alpha one Gen I
                  under restoration
                  Complete HD pictures set here

                  Comment


                  • #10
                    Question for the experienced rebuilders:

                    how are the stringers, deck built by the factory??

                    the following pics are a piece of deck/stringer

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                    one can see that the stringer, cleat and deck are glassed from the inside with a very little to none glass on the bottom part of the stringer.
                    The stringer was not touching the hull, there was some foam in between them, also the glassing on the outer part of the stringer is very thin and not reaching the top of the wood.

                    this is what is left of the glass once the plywood and foam are peeled off.
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                    any idea of how they do it?
                    1987 Sea Ray Seville Cuddy Cabin - 5.7 mag Mercruiser alpha one Gen I
                    under restoration
                    Complete HD pictures set here

                    Comment


                    • #11
                      more curiosities :-)

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                      This is a view of the compartment between the fuel tank and the front cabin with the foam removed.

                      on the picture you can see that the stringer were not even glassed to the hull in this section. the foam can be seen betwenn the hull and the stringer.

                      another thing is the drain pipe which is not continuous up to the bulkhead. the foam there was a bit wet and dirty , you can still see the black mark on the hull. besides that the foam was not completely water logged

                      am I supposed to rebuild it like that? I would guess not.
                      anyone already seen this?
                      1987 Sea Ray Seville Cuddy Cabin - 5.7 mag Mercruiser alpha one Gen I
                      under restoration
                      Complete HD pictures set here

                      Comment


                      • #12
                        Unusual to find that sort of construction, particularly in a Sea Ray. Not sure if they were trying out a new construction method, or if the crew was having a bad day.

                        It looks like the stringer and decking section were glassed at the cleat/right angle before installing into the hull. Based on the scarcity of tabbing, the foam is holding the structure together.

                        Now that you have cut into the stringers, what is 'the plan' to repair? Are you going to cut the rest of it out and rebuild, since the construction is suspect?
                        Best regards, Ted . . . . Cape Cod, MA

                        Current Boats: Formula 330 Sun Sport, O'Day Mariner Sail #3224, Sunfish
                        Past Boats: Catalina 22 Sail #10531, Formula 242 Sun Sport
                        Twin Mercruiser 7.4 LX MPI (0F802036, 039), Bravo 3's (0F806198, 199), Mercury 7.5 HP (1969), Johnson 4.5 HP (1980)

                        My Boating Web Pages: http://www.tpenfield.com

                        Comment


                        • #13
                          Originally posted by tpenfield View Post
                          Unusual to find that sort of construction, particularly in a Sea Ray. Not sure if they were trying out a new construction method, or if the crew was having a bad day.

                          It looks like the stringer and decking section were glassed at the cleat/right angle before installing into the hull. Based on the scarcity of tabbing, the foam is holding the structure together.

                          Now that you have cut into the stringers, what is 'the plan' to repair? Are you going to cut the rest of it out and rebuild, since the construction is suspect?
                          I agree with Ted. My best estimate is to remove everyhting and make the boat safe. It'll be better than factory cause mass production is what killed the best builders. Sales, speed and again sales. No real quality control.Now that you see it as it was made now you can figure out the better ways to make this boat float for a long long time.
                          KC
                          Most times I'm wrong, Most times I stand corrected..But...Sometimes I'm right.
                          1983 SportCraft Deep V OSFF 222 Cuddy Rehab
                          https://forums.iboats.com/forum/boat-...ddy-walkaround
                          https://forums.iboats.com/forum/engin...-new-fuel-pump
                          www.flotationfoamsolutions.com

                          Comment


                          • #14
                            Currently my plan is to look for the good plan

                            about the poor glassing i ran across other sea ray rebuild threads showing same type of pictures. For example kabookey with a 86 sea ray (i borrowed him the pic)Click image for larger version

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ID:	10544972 strange though that a "high end brand" take these shortcuts. Altough we do not have the full history of the boat i'm pretty convinced this is still the original construction.

                            for the rebuild my first idea was to make new stringers from the transom up to the existing one where they are in good shape. They would be bedded and glassed as per the techniques widely used here on the forum for example friscoboater or woodonglaas and manymany more (sorry for not naming you all 😁)
                            ​​​​​​​what concerns me a bit is that it would be different length for the port and the starboard one. Not sure how it would behave in use.
                            1987 Sea Ray Seville Cuddy Cabin - 5.7 mag Mercruiser alpha one Gen I
                            under restoration
                            Complete HD pictures set here

                            Comment


                            • #15
                              Sign up today
                              I am new and don't want to tell you what to do but. On mine i had my mind made up. If anything was wrong it was all coming out and getting all new. I wont ever get rid of mine. I just wanted to know it is all in good condition. And will last me as long as I need it to.

                              You already got the hard part out of the way. There isn't much left.

                              Just think of it. All new wood and glass. Assembled in a way that is 1000X superior to what the factory did. Then you actually take care of it and keep it dry. Biggest issue you will have is keeping it shiny.

                              Go out on your new boat knowing it is new. That is piece of mind.

                              It is a good looking boat I could see keeping it a very long time myself.
                              Dance with the waves,
                              move with the sea.
                              Let the rhythm of the water
                              set your soul free.

                              1987 Four Winns 170 Horizon.

                              Comment

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