19.5' Glasply build

[Jasonfast]

So this will be a bit of a repost and might not make total sense. I have this all posted on a local forum but it can't hurt to have a broader audience for some outside perspective. Bare with me while I copy and paste a bit.

So i was running my 17.5' K&C thremoglas and it's served me well. But i always dreamed of something bigger. We all have our dream boat in our minds but all I really wanted was an 80's hull. Maybe 20+ feet and new outboard power. I would restore it and it would be awesome. So I started browsing the local online classifieds. I found a couple really good hauls but nothing was right. I made a few offers on other boats but nothing felt right. Then I found this beauty. I went to go see it and the price was right in my budget. A 19.5' glasply. It was beautiful. Big and spacious. Far bigger than I was used to. But she was big. And heavy. Wasn't going to be towing it with my jeep tj. And my 1990 f-150 was a POS. So. What to do? Well the excitement got the best of me and I made an offer and was the proud owner of a new to me boat.

So this was how it sat at the storage place. I dragged it home with the ford and it was very apearant that the axle was bent and damaged. Leg was off. Needed a new shift cable. Motor hadn't run in a little while. Interior was rough. Hull Needed to be cleaned and buffed. Trailer lights were kinda working. But had agreat honda 4 stroke kicker. Newish SS prop. Stereo. Came with down riggers and the canvas was in good shape. Again. I was in love. But I needed a vehicle to tow this mammer jammer. So picked up an 03 GMC 1500 HD. Which cut into my budget for boat repair.

My current goals for this is to be able to hit the coho derby in port renfrew, BC oct 5,6. Past that. It will be a new interior, upgrade the wiring and a repower when the 470 goes.

First on the list was dealing with the axle. So the trailer went up on stands and cut the axle out. It was a drop axle and the spindle had a good 5-8* bend in it. Someone had tried to weld a peice of metal to support it but to me is irresponsible concidering the size of boat. If that busted on the highway?

Buddy of mine owns a local suspension shop so I ordered a new 6000 lb axle and 3500lb springs. Figured the boat was around 3000-4000 lbs. might as well get a beefy axle with strong big bearings.
The old axle was only a 3500 with old corroded drums someone had taken out of service. Surge brakes will also be on the menu.

The axle would take 2 weeks so in the mean time I had to become more familiar with the boat. Found a manual online for $15

And took to washing and polishing the boat.
Pre wash

After some pressure wash fun

Used some 3M boat compound. Took off all the oxidation and grime. Still have to wax.

I have been a little apprehensive in repairing the leg and reattaching. Only because I don't want to pay for all new seals just to find out something else is rotten and needs replacing. But after much research and youtube watching I'll be doing it. So Monday I'll order up some parts but today I managed to get the trailer back on its own tires.

 

[Jasonfast]

Axle came bare steel so some self etching primer and a coat of paint.

Put the leg on just so I could see if I could duplicate the problem and run the engine.

After a little maintainence she fired right up.

http://youtu.be/Elih06fbseA

 

[Jasonfast]

Well it kills me to pay someone to work on my stuff but with the amount of work I was doing and the daylight getting shorter and shorter and the derby being next weekend I was seriously running out of time. So on Tuesday I bit the bullet and took it to my buddies mechanic. He is the lead mechanic at a local marine shop and just moonlights on the side. After talking to him for like 40 min he seemed like a really good honest guy. So I was happy to give him the business. I'm also glad I did because he found some things that I wouldn't have and said other things were ok that I thought weren't. So I dropped the boat off at his place and left feeling better. Till I went back the next day and was told the leg was shot. And repairing it would out me over my $800-$1000 repair budget. I was a little bummed and in most situations probably would had just took a step back and reevaluated things but I really wanted to go to this derby any had 4 other buddies that were supposed to go with me. Luckily all my obsessive late night online classified searching has paid off and saw a used alpha 1 leg for $500 on a local site. Got it for $300 and it looked to be in good shape. Ujoints we solid. Was told it had a new impeller. The oil was new so was unable to see if it has flakes and metal chunks like mine in it. Being this was only my second boat purchase I am now more familiar at what to look for in a purchase. Live and learn. So he's replacing the shift cable and shift cable bellow. Gimbel bearing and exhaust bellow are in good shape. He fixed some electrical issues and just gave the boat a good once over. Said spite these extra costs he still believes I got a good boat for the price I paid. So that's always good to hear. Probably could have paid less knowing what I know now but here we are. I am back on track for a schedual. Hoping to get the boat back by Tuesday.

 

[Jasonfast]

So derby was great. Amazing weather and great fishing. Winning coho was 19.12 lbs. grand prize was a little over $10,000. I'll be the first to admit that this trip was rushed. We barely made it (timeline wise). Boat was all new to me. But t was fun none the less! So 4 of us went. A long time friend of mine and two buddies from work. The two guys from work rented a 24' camper trailer and left victoria around 2pm. Got to port renfrew at like 6pm. Me on the other hand had to wai till my buddy got off work at 6:30pm and we went together.

Picking up my buddy.


It was around 11pm by the time we found them in the sea of campers and boaters. We launched the boat and moored it in he slip we had rented. And had some drinks and food and hi the sack at around 2. Up at 5am to fog. Around 7 it cleared and we headed to the boat to get our fish on. We load up with all our crap and run the blower and go to start up and nothing! The starter would spin but not engage the flywheel. Some gental taps with a downrigger ball (no hammer) wouldn't help. So pulled the starter and it looked ok. Added power and the sprocket would shoot forward. Ok so reinstall and the 470 fired right up. We were pumped. Only lost about 40 min of time. We follow the long line of boats down the river out of the marina. It was low tide and there was only about 3-4ft of water so it was slow going. We enter the harbour and I can not get up on plane. Max out at 9mph at full throttle. I was dumbfounded. Could not figure it out? Was it the new leg? Was something wrong? So cr just trolled out the 10 miles to the fishing grounds dropping crab traps as we went. We get out there fire up the honda kicker and we were fishing!

Buddy holding around a 6-8 lbs er

Other buddy holding a 10-11 lbs er

Even made grilled cheese on the alcohol boat stove. Great day. But then The kicker keeps stalling to the point I can't keep it running. So I decide to troll on the main motor. She ran great all day. 700rpm at about 2-3 mph. And we were slayn' fish. Hit after hit after hit. The motor happy temp in 160 on the gauge. It started to climb a few times up to 175 and once to 180. So we'd pull up gear stop and add some fluid. Temp would lower and we would be all good. Spent about 10 hours out on the water total. Amazing day. But we had to get in because the lower tide would not allow us to enter the mouth of the marina.
So we grab our traps.

And head on in

I was really confused why we couldn't get up on plane earlier but after some time to think about it and feel the boat out and is it ran I figured we were just too heavy. I weighed the boat at the truck scale on the way home today and it was 2300kg. Thats just over 5000lbs. So minus 800lb ish for the trailer that puts the boat around 4500lbs. Add 600lb of man another 200 for gear and a lot more for fuel (filled all three tanks) she must have been well over 6500lbs. On the way home after burning a bunch of fuel she would get up to around 15.8 mph. So a re prop is in order. For an immediate fix.

 

[Jasonfast]

There is a sand bar at the mouth of the entrance to the river to the marina and at low tide it Leaves about 2' of water at low tide. So we cross and this big mofo of a bay liner (28' ish) comes in and was too far to the right and they hits bottom. They were stranded. We turn around head back behind them to pull them backwards. And I guess in all the excitement I wasn't watching the temp gauge because while I was trying to pull them out the motor over just cuts out. And won't turn over anymore. Now we are stranded. We set anchor. The guys in the bay liner jump out of there boat and start rocking it and with that and some waves coming it the get it free and use their kicker to troll away. Leaving us stranded now and take our rope as well. Didn't say thanks or nothing. Wasn't impressed. Another boat behind us tows us in and we make it back after waiting an hour or two for the tide to come up a bit.

So we pull the boat out of the water and go feast on crab. Didn't get to fish today (2 day derby) but with all the excitement we were pretty pooped anyways. So I get the boat home and I pull the plugs. Back two cylinders are full of water. So I'm assuming head gasket. So I dig on in since it was a nice day out. With the plugs out I crank the engine to push out most of the water and listen for any mechanical damage. It all sounds ok. No busted internals.

Intake off

Have to pull exhaust manifold as well to get the head off.

And a row of head bolts are under the rocker arms. So off come the rocker and push rods.

Off comes the head

Oh ya. There's your problem right there!

So I'll order some new gaskets. But still not sure why I was loosing coolant at first. If the two were related? Or is it still leaking else where? But ya. This also sealed the deal for a re power. Found a 351 Windsor on used victoria. So if all the parts are complete and in good shape ill have a new engine to go in. We did this on my brother boat and with the purchase of a core engine, Full rebuild, convert to EFI and build a custom ecu we got it to around $2150. So I'll be sure to post up about that when it happens. This Xmas I'm assuming. But spirits up and I love the boat. Handled the open water great.

 

[Jasonfast]

As for out board conversion. I don't think I'll do it to this boat. You never know. But not right now. As for the motor swap. I say 351 but that only because we've done one before. I got lucky and there seems to be no internal damage. I was pretty tired last night so I'll go over everything a little better. All I did was tear down. Clean up the water and give everything a coating of wd-40 to stop it from rusting. I will drain the oil and have a gander.

I need to research more and see what will fit. The 470 set up is pretty narrow. But bottom line is there isn't enough power. I want around 300hp of output. With the performance parts and EFI with custom tune we were getting that we feel if not more. Parts could be had at summit racing. But it all depends on fitment.

 

[Jasonfast]

Well all parts said and done were $80. As for the rest of it. If it goes it goes. I've got bigger plans than the 470. I'll do what I can. Clean her up. And if the 470 wasn't meant to be then so be it. I'll have a new boat anchor!

 

[Jasonfast]

Well alright. First off happy thanksgiving to any other Canadian members. Saved some of the work for this weekend when I headed up island to my parents place. Dad has a way better shop setup than me. He has a 4 bay garage. I have a driveway. Anyways picked up head, intake, exhaust and valve cover gasket along with a new oil filter and oil. Grand total of $95 so that's awesome. As for the water pump, couldn't find a part # for the water pump so may have to go to merc directly. Was at napa and they supply marine parts. For starters I took at look at my prop and it is a 14.25 x 19. Mechanic that did my leg suggested a 14.25 x 17. When I only had $50 in gas (around 40 L) and just me and a buddy max speed was 29.5 mph (as per GPS). Fully loaded I could get on plane. So I'm looking for a smaller prop.

Till then I focused on getting the engine back together. So with everything torn down it was time to do so cleaning.

Since the head was off we figured it was best to do a full tear down and inspect. Once it was all torn down we realized it was in pretty good shape and didn't need it but we were all ready there so. Ya.
Removed rockers and pulled the valves

Keeping it organized.

Started by cleaning all the matin gasket surfaces

Surface rust from blown head gasket

Almost there

Once all the real messy parts were dealt with it was time to lap the valves. They weren't in terrible shape but had some pitting and could use a little tune up.

Some lapping compound

 

[Jasonfast]

Still some lite pitting on the seat surface

Perfect.

Only 7 more. Beats the last 32 valve motor rebuild. That's a lot of elbow grease!

Once all the valves were lapped I took the head out side to degrease and pressure wash.

Much better

And blew out all bolt holes and cavities with compressed air.

 

[Jasonfast]

Oil valve stem

Spring seat

Oil seal

Spring and retainer

Little grease on the locks to hold them in place

Compress and repeat

 

[Jasonfast]

The manual spec'd that one should decarbonize prior to install.
Before

After

New gasket

Head

Pushrods back in

Rocker arms

Some prelube

Cover

Exhaust

Then I ran out of time. Continue on tomorrow.

 

[Jasonfast]

The leg was just something I needed help on. But now I am fairly familiar that if anything else goes on the leg I'll be doing the work. So boat seems to be good to go. Ran it. Then turned it off. Scoped the cylinders with a small imaging camera after and saw no moisture or anything after letting it sit. No more water in the oil. So.... Seems all good? Will just keep an eye on it. I put on the other prop and it was a 14.25 by 18 I think. Couldn't really read the numbers. Turns out the stainless prop was 14.25 by 20. So I hope that helps a little bit more. As for now I think I'm done. Might upgrade the trailer. Electrical and interior for sure this Xmas.

Now the part that excites me. I think we've settled on a 302 for a repower. We found a complete marainized motor for a somewhat reasonable price. We will offer what we think is fair and if it happens great. Already started collecting EFI parts to convert it over

Also my dad and brother both have Lexus sc 400 that they converted over to manuals and tossed factory ford superchargers onto.

There is no real aftermarket support for these Lexus 4L V8 and what there is is brutally expensive. So my dad made his own manifold and had a local welder weld it up. He sells these kits on a Lexus forum. Anyways long story short we have a few extra supercharges kicking around and figured. Hey. Why not charge the 302? The charger will fit the motor as they come off 302 mustang motors. You can find them cheap as guys upgrade their chargers for rouch racing stuff. The question I'd if we will have room around all the heat exchangers and such. This will also be done around Xmas time. So I'm excited. Here a motor setup we are doing for a guy out of North Carolina.

 

[Jasonfast]

So motor has been running well. Went out on Saturday night after work and it was amazing.

Video: http://youtu.be/evBcvpqpI10

But I definately have a coolant leak. It's not going into my motor. 100%. Making me think perhaps there is a crack in the exchanger or exhaust manifold and it's going out the exhaust? I found a heat exchanger locally and may pick it up. But we will see.

More importantly found a 302. For free. Even comes with a boat.

The boat is pretty much toast and I'm not gonna do anything with it. The motor is complete but can't be seen running. Also comes with an alpha one leg. But for free who cares. Just one step closer to a better boat.!!!

 

[Jasonfast]

So I think I have a problem. A boat problem. A boat hoarding problem. Before I joined the site I had one boat. Like a normal person. Then I bought the glasply. And then I bought 2 more. Who owns 4 boats? Anyways. I knew you guys would understand and not judge me. But surprisingly enough the WAR is at a solid 9.5. Or in my case GFAR.

Plans have changed slightly. I ended up pulling the 302 from the Apollo. Solid it to a guy for $200. Sold all the 302 EFI parts for another $100. Which covered the dump fees of the Apollo. I then took the $200 and got this gem.

1975 21' (trailer not included- let me borrow it for a week)

The interior is striped and the stringers are not rotten at all but have been cut in some strange places.

The canvas is in rough shape by will keep the bows and adapt them to mine and can use the existing canvas as a template.

I REALLY want to keep this one. REALLY! But have no where for it and it's more work then I'm willing to do. I am heading back to school for degree number 2 in sept. So I need to be realistic. I will take what I need from her and then unfortunatly it's a trip to the dump.

And the main reason I bought her.

351

All the pumps, trim tabs, rams and everything are in better shape than what I already have.

 

[Jasonfast]

So I started stripping out the 21' GP for the motor and stern drive. Also took all the electrical pumps rams ect ect. It was raining like a mofo! Where has been amazing for the last 3-4 weeks and then the day I wanna work on the boat. BAM!

Motor came out like a dream. Done in 20 min.

I'm looking forward to this beauty! To go from the 150 ish hp of the 470 to some 300+ I'm gonna get out of this 351 I'm loving it.

 

[Jasonfast]

Now the rest of it. Well that took more than 3 hours!

Got the transom plate off

Any body use this on their boat? I don't think the 19.5' has it?

Lucy found some entertainment

The gimble house was quite the challenge to get off. But we made it happen.

Loaded it all up and ended up with a good score. Stripped as many stainless steel fasteners as I could.

 

[Jasonfast]

i went up island to my parents place over Xmas and took my 19.5' and the donor motor up. the motor now has a nice warn heated shop to sit in instead of under a piece of plywood in my driveway.





Some of the old 302 EFI parts we had previously collected some young guy bought as he was swapping his hi mileage 351 for a 302. we gave him all the 302 EFI and intake parts in exchange for his entire 351w EFI. so now i have all the EFI parts as well. Santa must of also heard i was working on my boat because he brought me a bunch of goodies.

Mega squirt stand alone ECU (some assembly required) just kidding. alot of assembly required!






and a Walbro hi pressure in line fuel pump



Now i am not even going to pretend i know anything about this ecu and building it. this will be the 7th vehicle my dad has done with this system. we did my old truck. a couple of super charged lexus's, my brother old toyota, his master craft ski boat and now my boat. the tune will be extremely easy as we have the previously saved tune from my brothers boat. mega squirt has many baseline tunes available for download with their software to get pretty much any engine at least running. the tune is more or less up to you from there. can be done on the fly with a laptop in the diagnosis port of the ECU or taken to a professional engine tunner or buy a custom tune based on your parameters from a 3rd party company.

these ECU are also self learning with a wide band O2 sensor. we were able to weld in a bung into the exhaust side for tuning but due to reliability and welding to the cast exhaust we swapped it out for a normal one after the tune as for fear of the weld cracking after repeated heat cycles.

so in the next few weeks my dad will assemble the ecu. solder all the resistors and transistors and enter the matrix and what other fancy smart words on can say and get it done. ill be sure to post pics of the assembly process. after that it will be fitting a wide ass 351 in place where a narrow 470 used to live.

 

[Jasonfast]

So that all took coarse from about sept 2013 to dec 2014. This is all from the last 6 months. Xmas 2014

Well I know I haven't been a very active member this year but the new year looks promising. I was having some overheating issues and turns out it was a faulty heat exchanger. Now because I am not keeping this engine I didn't want to spring for a new one in the tune of $500 ish. So from my brothers mastercraft ski boat we had an extra laying around. Obviously the bungs we all in the wrong spot so some quick fab and a trip to the local radiator shop to solder it all up she seems to be working just fine. I'll follow up with some pics on that soon. Steering also seized with lack of use. Will have to address that too. But for now we start with the rebuild of the trailer. The trailer that came with the boat was in disrepair. The axle was bent and the suspension was shot. Early on in this build if you look back I replaced the axle with a bigger 5k or 6k (can't remember) and upgraded the leafs. However the trailer wasn't made to handle weight of the boat and with the rapidly growing rust was starting to buckle. So we upgraded to 5" C Chanel. I've been busy with work so the old man got a head start on the project. I promise from here on out the pics will be many and thurough. But forgive the lack here at the start.

I've chosen to use POR-15. I'm familiar with it. I've used it. I know it works. You guys mentioned a lot of other neat products and given more time I probably would have tried them but this is the route we are taking. Dad already mocked up the trailer without me as we have limited time to do this. So all the jigs and angle and thinking has been done. He pre welded all the cross bracing and wire chases. Main rails are cut and the stansions are already mocked. We are converting from rollers to bunks.

We have clean metal so we start process with an acid wash

 

[Jasonfast]

Something isn't working right here? I'll post the rest once i figure it out

 

[Jasonfast]

So looks like I uploaded some directly to a website and don't have them in my photo bucket. Missing a bunch but pretty much just making a trailer

[haven't found any marine grade anti seize yet by will address the issue before she goes into the salt.

So back to the boat. The bottom of the hull it quite close to the end of the Tounge and on some launches it looks like it will make contact.


So I fabbed up a roller


And set it in place. Launched the boat again so I could faster the bunks and finish welding

Fastened all the stainless brake lines