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  • #31
    Re: 1964 15' Starcraft Aluminum Runabout Project

    So far, not too impressed with Rustoleum Marine paints.

    I put the second coat on the interior 8 days ago and it has been drying/curing since then, and we have had mostly all 85-90 degree days, so it's been good and hot. While I was fitting the plywood, I bumped the gray in a few spots and it took chunks of paint off. I also put a couple pieces of masking tape to mark certain spots during my planning, and forgot to take them off. I carefully peeled them off and with one of them, a big chunk of paint over an inch square came with it.

    I used Rustoleum Marine Metal Primer over old paint that had been sanded & scuffed. It was applied exactly according to the directions on the can, as was the Topside Marine gray. It was new gray paint that came up with the tape, not the primer. I keep it covered with a tarp when I'm not working on it, and when I take it off, I can still smell the paint pretty strong.

    I would have thought it would be beyond that fragile stage by now.

    A little help from others:

    On your rusto, How long did you wait to put on your second coat?
    Not sure exactly...the second coat was between 24-36 hours later I'd say.

    What method of application did you use?
    Used a roller mostly, and a brush in hard to reach places.

    How Thick of a coat did you apply?
    "Normal" thickness, meaning not too thick and not too thin. Don't know how else to describe it; each roller-full covered maybe between 1-2 sq.ft.? Just a guess.

    Did you use any kind of thinner? You might want to try Direct Sunlight.
    Nope, didn't use any thinner, and it did have at least 2-3 days of direct sunlight within that 8 days. It has been very humid most of the time however and I wonder if that has something to do with it.

    I won't be working inside the boat again for several days, so I'll let it age and see how it is then. I believe that painted stuff generally takes longer than the mfr. says before it's really ready to use.
    Last edited by lakelover; November 21st, 2011, 07:17 PM.
    My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

    Completed condensed version: The Permanent Vacation

    Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

    Comment


    • #32
      Re: 1964 15' Starcraft Aluminum Runabout Project

      Double-checking my transom height...I might have to reshape my new transom board & shorten the height slightly to ensure proper mounting height for the Johnson 50.

      Last edited by lakelover; November 20th, 2011, 07:31 PM.
      My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

      Completed condensed version: The Permanent Vacation

      Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

      Comment


      • #33
        Re: 1964 15' Starcraft Aluminum Runabout Project

        Originally posted by Woodonglass View Post
        Hey LL,

        I re-read everything and I got another question. Is this the PRIMER you used.

        http://www.rustoleum.com/CBGProduct.asp?pid=397

        If not then this MIGHT be the problem. Aluminum needs to have a Self Etching Primer to ensure proper adhesion.

        I'm just sayin...
        Nope, I used this, but I was applying it over previous sound paint (or in some spots, self etching primer), not bare aluminum:



        It's solvent-based, not latex.

        Followed the directions on the cans. What peeled off with the tape and the nicks were just the new layers of paint, not any of the primer I put down. The primer was surprisingly solid.
        Last edited by lakelover; November 20th, 2011, 07:35 PM.
        My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

        Completed condensed version: The Permanent Vacation

        Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

        Comment


        • #34
          Re: 1964 15' Starcraft Aluminum Runabout Project

          My Starcraft is getting further and further away from original.

          Today I was measuring and fitting for seats, controls, etc. and when it came right down to it, I'm going to have to leave the dash tray out permanently. Kinda disappointed after stripping all the paint & old glue, sanding smooth, & buying vinyl. I'm pretty tall and my knees bump against the tray. There's just not enough room for me once I get the seats and steering wheel and control situated. I have the 10 degree Teleflex mounting adapter that I'll use anyway just to give a little more knee room.

          I bought a BRP replacement control for my 50 and those newer controls take up a lot more operating space than the old 2-lever speed & shift controls. I tried every which way from Sunday to convince myself the dash tray would fit in the plan, but in the end, there's just not enough room for comfort.
          Last edited by lakelover; November 22nd, 2011, 08:22 AM.
          My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

          Completed condensed version: The Permanent Vacation

          Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

          Comment


          • #35
            Re: 1964 15' Starcraft Aluminum Runabout Project

            I spent the day fabricating a new board for the control and cutting out seat boards. The control mount board had to be completely redesigned and adapted to fit the newer controls, made larger and thicker. I screwed up the first time and cut it wrong. Then I got my act together and remeasured, cut drilled and glued. I needed to increase the thickness for clearance for the lever travel, and the high idle lever to operate. I'll apply some epoxy to waterproof and then plan to cover it with vinyl.



            Cutting the seat boards was very frustrating, until I finally figured out what was going on. I measured and re-measured and measured again, thought it was right, laid out the cuts and cut the front board out. It was way off and I was out of 3/4" exterior by then, so I had to hook up the trailer and make an excursion to Lowe's. Got back and started in again, and darned if I didn't keep coming out with a different measurement every time. Unbelieveable, I didn't think I was that bad at it. I was using my measuring tape and an excellent 4' T-square that I use for cutting mats for photographs. After my umpteenth calculation, measurement and transfer to the plywood, it was screwy again. OK, really started thinking and checking things out and here's what I discovered.....my !&%#***! 4' T-square is only 47-7/8 inches long!!! Never noticed it when measuring from the right end! So watch out for stuff like this!



            You wouldn't think it would make that much difference, but I was using them interchangeably, having to measure certain distances from the center to the edges etc. Well, from now on, it's only a square, not a ruler too.

            So after figuring that out, the re-cut went really smooth and it fit right in, and the measuring & cutting of the rear seat board did the same. Notice that I made the rear board deeper front-to-back so I could set the seats back a few inches to avoid the front & back seatbacks bumping each other.





            When I bought this boat, I didn't realize at the time just how much of a rebuild it was going to be, but as I got into it more and more, it turned into a lot more work than I imagined. It was enjoyable, but some days I wondered "What was I thinking?". I didn't really have a clear vision of whether I just wanted something to get on the water, or wanted to do a more thorough update & resoration. It's a good idea to decide that before starting!
            Last edited by lakelover; November 22nd, 2011, 07:52 AM.
            My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

            Completed condensed version: The Permanent Vacation

            Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

            Comment


            • #36
              Re: 1964 15' Starcraft Aluminum Runabout Project

              Epoxy-weird experience Nothing serious, but strange.

              I was finally back at it today putting more epoxy on, second coat for the floor and first coat for the seat boards etc. I mixed & applied one batch (US Composites 3:1 type) and all went well. I mixed a second batch & put on a fresh roller, and after about 15 minutes, my plastic paint tray got hotter and hotter, and then after I had dipped the roller and started to roll it out, it just suddenly gelled on the floor board in big stringy gobs instead of rolling out. I quick got a piece of cardboard and squeegeed off the gobs so I wouldn't have to do a ton of sanding after it cured. Then I went to pick up & discard the tray and roller and the tray bottom had begun to melt and the mixture was smoking. Outside temp. was 78 and weather dry & sunny.

              For some reason, maybe a mixing error or temperature conditions(?), it suddenly started to cure superfast. No serious consequences, but never had this happen before, using the same materials & technique. Very bizarre!

              After removing gobs:


              Tray:
              Last edited by lakelover; November 22nd, 2011, 07:53 AM.
              My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

              Completed condensed version: The Permanent Vacation

              Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

              Comment


              • #37
                Re: 1964 15' Starcraft Aluminum Runabout Project

                After all the reading I've done on the paint subject, I've decided to go with the Easypoxy paint. But I want to mention that the durability issues I had with the gray Rusto Marine on the interior seem to have abated since the paint has aged significantly.

                I learned a couple things about working with vinyl today, applying it to my fabricated plywood control board with Weldwood contact cement.

                1) After you apply the cement and are waiting for it to set up, the vinyl gets pretty soft and stretchy, and you need to be more careful of wrinkles.

                2) When you apply the cement and walk away to do other stuff while it's setting up, the edges of the vinyl tend to curl up onto themselves and get stuck.

                3) It's harder than it looks to figure out where to make the cuts for wrapping a shape other than flat and geometrical. My board has two curved corners and single and double thickness.

                In the end, with a lot of messing around and "custom" hacking and cutting with scissors and a stanley knife, it came out not looking too bad for a first try. At least most of the mistakes are on the back and in more obscure spots.



                That will probably be the extent of my vinyl work. I had planned to use it in the dash tray, but decided to leave that out to make more knee room for myself.

                I also made progress with primer and paint applied to seat and floor boards and the transom board.
                Last edited by lakelover; November 21st, 2011, 07:24 PM.
                My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

                Completed condensed version: The Permanent Vacation

                Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

                Comment


                • #38
                  Re: 1964 15' Starcraft Aluminum Runabout Project

                  Last weekend I got a couple more coats of paint on the backside of the floor plywood, seat boards & transom board. All these coats of paint are running my paint bill up because when I was figuring how much to order, I underestimated how many coats I was going to apply. Also needing a lot more foam rollers. For the final couple of coats of Rustoleum on the top of the floor, I have the anti-slip additive to mix in. I'm curious to see how well it works.

                  I made a template of the dash for further work and checked out the fit of the new Teleflex rack steering, it's going to work out OK.

                  More progress on the floor... I laid out the foam and fitted in the rear pieces, after putting marks on tape on the sides over the centers of the ribs, and marking down the center of the floor. After marking out where the rivets would go and drilling carefully thru the plywood and aluminum, I injected a hefty dose of 5200 into the hole before putting in the rivet.



                  A bendable aluminum yard stick helped in lining up the marks along the cruvature of the hull for drillling.



                  Afer putting in the first few rivets on the first piece and moving around on it, I knew right away that the excessive squeaking caused by the movement of the epoxied and painted plywood against the foam would drive me crazy. So I drilled out the rivets I'd put in and started over.

                  I came up with the idea of putting 4 mil clear plastic between the foam and plywood, and it has totally silenced the floor. I think it will hold up well protected from the UV, since this is the stuff that never rots buried in landfills. As long as it doesn't break up into little pieces and clog up the under deck drainage, it should be OK. I was surprised how well it worked.







                  Next step is to continue with the front decking pieces. After they are in, I have to work on the seat boards and supports, and then I'll be painting the floor.
                  Last edited by lakelover; November 22nd, 2011, 07:55 AM.
                  My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

                  Completed condensed version: The Permanent Vacation

                  Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

                  Comment


                  • #39
                    Re: 1964 15' Starcraft Aluminum Runabout Project

                    First day of retirement! and the floor is done. It's not perfect, but considering this is my first rivet job ever, it's not too bad. Getting the front sections in place with that bend made me sweat a little, but it worked. The thing that pleases me the most is that I overcame that horrible foam-squeaking and it's completely quiet when I walk on it.



                    I'm going to put vertical supports under the centers of the seat boards for added strength, so I gorilla-glued two pieces of 1/4" ply in place to fasten them to. I'm going to stabilize the bottoms using aluminum right-angle stock screwed to the supports and floor, so that total 1/2" floor thickness under the supports will give something more substantial for the screws to grip.





                    A while back I purchased some SS nuts, bolts, washers & screws for the seat brackets and reassembling the transom, so I have to mention this great source. I got them at Boltdepot.com where you can order almost anything you might need in any quantity with reasonable prices and shipping. They come in small zip bags, completely labeled, sent exactly what I ordered and I was impressed that the count was exactly right. Quick service too.

                    Last edited by lakelover; November 20th, 2011, 07:51 PM.
                    My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

                    Completed condensed version: The Permanent Vacation

                    Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

                    Comment


                    • #40
                      Re: 1964 15' Starcraft Aluminum Runabout Project

                      Dry fit of the seat boards & supports...they are pretty solid and will withstand a good amount of weight and will also stiffen up the hull.



                      Last edited by lakelover; November 20th, 2011, 07:52 PM.
                      My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

                      Completed condensed version: The Permanent Vacation

                      Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

                      Comment


                      • #41
                        Re: 1964 15' Starcraft Aluminum Runabout Project

                        Originally posted by QUIC View Post
                        Hello
                        I have been watching your prgress, you are doing a great job. I have a 64 jet also and there was no floor when I got it and Ive been using it that way but you have inspired me to put one in. Did you use 1/4 inch plywood? I know you were given the rivets by another member But where can I get them? Thanks
                        Quic
                        Yes, that's 1/4" exterior plywood. Anything thicker and I don't think you'd be able to get the curve in there. My original floor was pretty rotten and came out in small pieces, but I was first able to make rough templates on big pieces of paper before removal. I'm pretty sure it was the original by Starcraft.

                        The floor's sealed with: 2 coats of epoxy, and then the underside and edges have Rustoleum primer and 2 coats of Marine Topside paint.

                        When I get finished, the top of the floor and the seat boards will also have primer and multiple coats of paint.

                        If you use flotation foam, I definitely recommend putting the plastic sheet over it to suppress the noise of any movement. Otherwise it squeaks like crazy.

                        As far as rivets, there are many places you can get them online, just google pop rivets and check out what comes up; broad head are best for the floor. Or maybe you have a Fastenal or similar store near you. The rivets I used are 3/16 dia. x 3/4 long. The broad head is 5/8 dia. You could probably get away with 1/2" length with the 1/4 plywood.

                        I just thought replacing the floor ply would make it a little easier on the feet esp. since I might be barefoot in the hot weather. I know the naked aluminum floor can be kind of painful if you step on the ribs.
                        Last edited by lakelover; November 20th, 2011, 08:02 PM.
                        My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

                        Completed condensed version: The Permanent Vacation

                        Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

                        Comment


                        • #42
                          Re: 1964 15' Starcraft Aluminum Runabout Project

                          I have been making progress laying down coats of paint on the seat boards, supports and transom board. I had to order more marine primer for the floor (@$23.99/qt! I had considered cheaping out and getting Rusto's cheaper all-purpose primer, but after digging into the documentation, saw that is wasn't for applications subject to repeated wetting or standing water.
                          -------------------------
                          I just received a reply to an email I sent Rustoleum regarding this issue:

                          The Marine Primer was specifically formulated to adhere to wood and fiberglass
                          surfaces and to be compatible with our Marine Topside paints. Our CoverStain
                          primer can be applied to both wood and fiberglass surfaces, as well as PVC,
                          aluminum, etc. It also is designed to help block tannin stans and other bleed
                          that comes out of wood siding, shutters, etc. While the Marine Topside paints have not been tested over the CoverStain primer, I would not see any compatibility problems with this application.


                          Even though the "regular" primer is only $8.99/qt., in light of the conditions it will be subjected to, I'll bite the bullet and go with the marine primer.
                          Last edited by lakelover; November 19th, 2011, 09:37 AM.
                          My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

                          Completed condensed version: The Permanent Vacation

                          Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

                          Comment


                          • #43
                            Re: 1964 15' Starcraft Aluminum Runabout Project

                            A lot can go wrong when you're painting!

                            The primer came in and I got a good coat laid down, then the next day started with the first coat of paint. I started and everything was going along pretty well, when suddenly a flurry of soot particles began descending on the wet paint. I couldn't figure out where the heck it was coming from, thinking that a neighbor might have started a fire in a wood stove or fireplace, when I realized it was coming from my own oil fired boiler.



                            So I went in and turned it off and finished that coat. After the paint was dry, I managed to vacuum a good portion of the soot off.

                            I mixed in the ground pumice and got a coat down. I have to say that the anti slip is gonna work great, I can tell already. Even though it's sort of hard to get the stuff evenly distributed using a roller, it's dry enough now that I can rub my hand over it and even in the thinner areas, it practically eliminates any slip, so I doubt people will be slipping on it when it has water on it.



                            I will apply the second coat with a brush, it's easier to control the distribution of the grit.
                            Last edited by lakelover; November 20th, 2011, 08:05 PM.
                            My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

                            Completed condensed version: The Permanent Vacation

                            Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

                            Comment


                            • #44
                              Re: 1964 15' Starcraft Aluminum Runabout Project

                              The interior painting is finished. Here are some things I learned about Rustoleum and using anti-slip additive:

                              When lay down the anti-slip additive, I definitely recommend applying by brush rather than roller. With the brush, you can control the distribution of the grit a lot better. Also, put three coats on.

                              To summarize, the floor has:

                              2 coats of epoxy top, edges and bottom;

                              1 coat of Rustoleum Marine primer for wood and fiberglass all around;

                              2 coats of Rustoleum Marine topside paint all around.

                              Then on top of that, the top surface has three coats of paint with the grit added.


                              The rivets are all sealed with 3M 5200, as will be all screws needed for the seat board supports. Overall it's quite well sealed, I hope my efforts are rewarded with durability and longevity.





                              Brushing this on makes a weird swishing sound, like sweeping...great stuff though, I'm curious to see how it will hold up to use.

                              Last edited by lakelover; November 21st, 2011, 07:33 PM.
                              My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

                              Completed condensed version: The Permanent Vacation

                              Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

                              Comment


                              • #45
                                Sign up today
                                Re: 1964 15' Starcraft Aluminum Runabout Project

                                The rear seat board gave me a little trouble on the port side because the holes didn't line up well. I think that's because my template was made from replacement boards from the PO rather than original, but I finally managed to get it all together.

                                I got all my SS fasteners, except the screws I used today for fastening the supports to the angle aluminum, from Boltdepot.com, they have everything. (I got all my angle, sheet and bar aluminum from onlinemetals.com) I like the locking nuts for the seat bolts:



                                This setup will be pretty solid, I think:





                                The anti-slip on the floor did tear up my knuckles pretty good during this work.
                                Last edited by lakelover; November 22nd, 2011, 07:57 AM.
                                My project (with index): 1964 Jet Star: https://forums.iboats.com/forum/boat-...nabout-project

                                Completed condensed version: The Permanent Vacation

                                Make a New acrylic windshield: https://forums.iboats.com/forum/boat...craft-jet-star

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