1959 Starcraft 16' Super Constellation - Winner 2016 Starmada SOTY Award

[ssdale]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration



Had a little time this afternoon (as another round of snow) fell to work on the StarCraft. Paintd the floatation box and forward hull. Finished sanding the dash and am trying to get the new bow support just right at the bow to accommodate the anchor assembly and everything else. Test fitting to find the sweet spot to fasten the dash. The dash is a real structural component of this boat and dictates how the final bow sheet metal fits (or doesn't).

I reused the bow plywood as it was in decent condition. Soaked it up real good with primer. Plus it fit under the bow sheet metal like a glove.

The tricky part is that the bow plywood all needs to be fastened to the oak gunwales before you can attach the bow sheet metal. So once the plywood is attached, there is no re-positioning to get a better fit for the sheet metal. The gunwales are not quite exactly the same curve as the sheet metal, but pretty close. Any advice would be appreciated!

Dreamin of spring,
Dale

 

[glnbnz]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

Wow it is really starting to take shape!! Very nice work ssdale

 

[Watermann]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

Had a little time this afternoon (as another round of snow) fell to work on the StarCraft. Paintd the floatation box and forward hull. Finished sanding the dash and am trying to get the new bow support just right at the bow to accommodate the anchor assembly and everything else. Test fitting to find the sweet spot to fasten the dash. The dash is a real structural component of this boat and dictates how the final bow sheet metal fits (or doesn't).

I reused the bow plywood as it was in decent condition. Soaked it up real good with primer. Plus it fit under the bow sheet metal like a glove.

The tricky part is that the bow plywood all needs to be fastened to the oak gunwales before you can attach the bow sheet metal. So once the plywood is attached, there is no re-positioning to get a better fit for the sheet metal. The gunwales are not quite exactly the same curve as the sheet metal, but pretty close. Any advice would be appreciated!

Dreamin of spring,
Dale

I'm liking your forward momentum and attention to detail. I would try to use braces, shims, clamps, straps or whatever else I had laying about to make the bow stay in the correct dimension as the bow cap and then make the adjustments to the under lying plywood to the correct fit rather than letting the plywood dictate the final shape.

 

[ssdale]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

Had not thought about using ratchet straps around the bow to get compression on the gunwales.! Thanks!

 

[kfa4303]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

It works great if you slide it a bit further back to help draw the sides of the hull together when reinstalling the benches too. When you remove them, the hull can sometimes flex outward a bit so when you go to install the new benches they seem too narrow even though you patterned them after the original pieces. I wish I, I mean my friend, had know about this trick before I went half crazy installing my seats for the fist time. LOL!

 

[ssdale]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

Great point about the benches kfa. My "friends" have done some dumb stuff too:lol: Have 1 of the original mahogany benches that did not crumble to dust. Like the dash, the benches are structural and I will take your advice when I get to them. Didn't get a chance to try the strap yet around the bow.

Did get a quick coat of finish on the oak gunwale tops and around all the stainless screws that will be covered by the bow plywood and metal before they are inaccessible. Also applied silicone to the screws when attaching the gunwales as advised by other posts here on iboats.

Dale

 

[boatbeginner1]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

Just found your thread while browsing through the forums. You are doing an amazing job!

 

[classiccat]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

Awesome job on those gunwales! That oak is going to really pop off of the white sides!!

 

[ssdale]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration


Thanks for the compliments and encouragement! Had a couple hours tonite to permanently attach the dash. Used the vintage screws through the dash and new stainless with acorn lock nuts through the gunwales.

After a few days with the bar clamp across the boat and the wooden angle brace helping shape the bow, it almost magically took the exact shape of the bow sheet metal. I take NO credit for it! (possibly the spirit of a previous owner?:faint2

Gave a lot of thought to how to attach the old bow plywood to the oak gunwales. originally they used the small metal staples that had mostly disintegrated. The ones that were left pulled through the plywood with barely a whimper. Needed something rust proof that would not pull out AND had a really nice big head that would spread the force out over a wide area of the old plywood and stay perfectly flat under the sheet metal.

Ended up using 1" galvanized roofing nails about every 4-5 inches. Drilled a small pilot into the oak for each one. I know it isn't very high tech, but it is done and they are there for keeps. Anyone is welcome to give future readers advice on what should have been used - I can take it:facepalm: Maybe I can cover the heads with Ducktape:lol:!

Dale

 

[kfa4303]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

I suppose if you wanted to be "correct" you would want to use either stainless steel, brass or bronze screws simply because they will never rust and can add a bit of bling, or you can counter sink them and cover them with plugs. Similar to the ones below.

Screws

 

[Watermann]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

My house has thousands of galvanized roofing screws and my roof doesn't leak. When I have to patch it they aren't rusted out either. Paint or maybe a sealer on top of the heads would give them even more protection under the bow cover. Did you use some adhesive between the oak and the wood too? Boat re-building isn't really a science and we have to improvise many times during the course.

 

[ssdale]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

I suppose if you wanted to be "correct" you would want to use either stainless steel, brass or bronze screws simply because they will never rust and can add a bit of bling, or you can counter sink them and cover them with plugs. Similar to the ones below.

Screws

Know what you mean. These will be hidden under the bow sheet metal and the bow plywood is so thin that to countersink would have really weakened-just clarifying

 

[ssdale]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

My house has thousands of galvanized roofing screws and my roof doesn't leak. When I have to patch it they aren't rusted out either. Paint or maybe a sealer on top of the heads would give them even more protection under the bow cover. Did you use some adhesive between the oak and the wood too? Boat re-building isn't really a science and we have to improvise many times during the course.

Have never seen a rusty roofing nail that was protected just as you say. I did dip each nail in silicone before driving. If you've ever tried to pull a nail out of oak-nearly impossible. I will either paint the heads or cover the entire bow plywood with a very thin sheet of plastic before installing the sheet metal. Can't decide if the plastic is a good idea or whether it might "trap" moisture/condensation. Any suggestions appreciated.

Dale

 

[kfa4303]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

Yeah, f it ain't broke don't fix it. If the nails are working and won't rust leave them be. I'm in saltwater 50% of the time, so I always try to make everything super rust proof, but if you're sticking primarily to freshwater you'll be fine. Is the cap strong enough to sit/layout on, or is mostly a cover? I wish I had the cap form my hull. I just love the way boats of this era look with the colorful glass caps on a tin hull.

 

[jbcurt00]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

No plastic, but self etching primer, primer & topcoat paint the underside too.

 

[Watermann]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

I agree ^^^ use primer and paint as a protective barrier.

 

[ssdale]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration



Quick before and after of mahogany dash. The stain was wet when I snapped this and looks a little harsh in the photo. Looks better in person. just wanted to get some stain on it to let it penetrate and protect while the project moves ahead.

Well today was the day I re-assembled the bow sheet metal:happy:. Its a relief to have it back together as I have never disassembled to that point before. I just sat the anchor assembly on the bow to make a better photo.

The paint on the bow will be need to be completely REDONE as I got in a hurry and the Caribbean turquoise OVERSPRAYED through a lift in my newspaper masking and got all over the port side of the white bow sheet metal:facepalm:. I just wanted to get reassembled and wait for warm weather to sand and repaint. Too cold for anything.



These are the seat brackets that I have cleaned up by hand using the technique learned here on iboats, thanks!. I love it when people post before and afters so bear with me.

Dale

 

[jbcurt00]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

Dash & all looks great.

 

[Watermann]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

Yeah, coming together and looking sharp!

 

[glnbnz]

Re: 1959 Starcraft - About to start restoration

Re: 1959 Starcraft - About to start restoration

yes definitely looking good!!!