1965 Starcraft Holiday Restomod

[boaterdave90210]

Hey Y'all,

Relatively new to iBoats and just started breaking down a 1965 Starcraft holiday I/O. My wife's grandfather used to take this fishing up on Lake Erie all the time until he forgot to winterize and cracked the block. After sitting for 7 years, I decided to take it off his hands to fix up, with his payment being a fishing trip when its done. So far, I've located a new engine (late 60's 120 HP instead of the original 110HP) ,ripped out the floor and touched up the Styrofoam. My plan is to get it running again, paint and restore the interior with a modern twist (wanted to go blue instead of green). Here's some pictures of my progress so far, and I'll update as I knock things out!

 

[SHSU]

Welcome!!

You are moving right along. Nice looking project boat and can't beat the price.

While you had the floor out did you take a look at the transom? I am guessing the key hole for the donor motor would be the same but don't know.

SHSU

 

[boaterdave90210]

Thank you! Transom is solid, and the keyholes and everything line up. Gimbal housing was still on the boat, and matches up to what the donor engine has, so may just use what is already on the boat.

 

[Watermann]

:welcome: aboard Dave,

Nice to see another Holly get put back on the waves again. :thumb:

If you've already done all the heavy lifting of pulling the motor then the transom replacement job is not that tough as is the motor mount as well. Also the transom assembly seal, gimbal bearing and bellows will need replaced so you don't sink the boat. I would add a new lower shift cable too while you're there. A couple special tools you'll need, with a drive alignment bar being most important, shift cable socket and hinge pin removal socket if yours has the torx looking pins that is, not sure what year those came about, maybe the MR era.

 

[boaterdave90210]

Thanks guys! I did find the alignment bar on amazon for when I line up the stern drive. I got the new floor installed and prepping for primer and paint now. Chrome and aluminum shine up pretty nice!

 

[boaterdave90210]

Had to make a new username - guess my email address was wrong lol

 

[SHSU]

Nice work. Moving right along. What are you going to top the deck with?

SHSU

 

[boaterdave90210]

I just did a coat of Kilz primer, then I plan on getting gray carpet to make it look nice. Once work slows down a bit, I'll grab some more pictures :distracted:

 

[boaterdave90210]

I know its been a few months, been a little busy this fall. I've got the carpet installed and a coat of paint on the topside. Working on the wiring harness next, and getting the engine bay prepped to drop the motor in.

 

[boaterdave90210]

Working on getting the trim motor working and getting the exhaust figured out. When going through the trim motor, it looks like the coils and internals are burnt up. I've tried to search for one, but I can only find a dual reservoir trim motor (this one is only a single reservoir). Anyone seen these before, and know where I could find a replacement?

Also, I'm taking a look at the exhaust setup from the old engine, and I noticed the exhaust is just a re-enforced rubber tube. It looks original and I plan on replacing it, but I wasn't sure if there was some sort of check valve that should be in there to prevent water from coming up? Currently it just does a J into the engine but I'm not sure if there should be something before that to keep the water out. I'll try to get a better picture of the setup next time I head to my parents house

 

[jbcurt00]

Had to make a new username - guess my email address was wrong lol

Which name would you prefer?

 

[Watermann]

Sorry to say but that original 1965 Mercruiser is pretty much obsolete. I suggest finding a complete Alpha series donor boat. The MC section here had some very knowledgeable people.

 

[boaterdave90210]

Yea that's what I was thinking. I have the motor, outdrive and gimbal housing assembly from a 68 donor boat. Was hoping I could mount it to the original 65 housing, but I think I may end up swapping everything out. That way I can have the dual reservoir trim, and the correct exhaust setup. Not the best picture of it- sitting in my family's barn for the winter.

 

[boaterdave90210]

Finally got out to the garage these past few weekends, removed the old gimbal housing, and did a test fit of the donor housing and all fits up well. (sigh of relief) About to order the bellows and tackle that project. I've heard they are a pain to get to, any tips to make it easier?

 

[boaterdave90210]

Which name would you prefer?

Hey sorry, just now seeing this I think boaterdave90210 is more fitting. Used to be my nickname in HS. Now 10 years later, I finally own a boat!

 

[Watermann]

Finally got out to the garage these past few weekends, removed the old gimbal housing, and did a test fit of the donor housing and all fits up well. (sigh of relief) About to order the bellows and tackle that project. I've heard they are a pain to get to, any tips to make it easier?

Most times just dropping the coin on OEM bellows is all it takes as they fit better and the rubber is more mailable.
Tools, I would get an alignment tool with bearing driver that also seats the driveshaft bellow ring seal on the A1 G2. Bellows expander tool for the job too.

 

[boaterdave90210]

So I ended up scheduling the bellows at a local marina - rather be safe than sorry when it comes to keeping water out of the boat. I did take the whole gimbal assembly off and painted the transom and stern side of the boat while I had it all off.

 

[boaterdave90210]

While I'm waiting on the gimbal, We got new Wise seats & made our own base (the plastic base that it comes with is flimsy and didn't like the look of them.) Covered with some leftover carpet and set into place. Made a new front motor mount as well, got my dad working on cutting out new plexiglass for the windshield, and other little odds and ends while we wait. The bellows should be done sometime next week, and hoping to get the windshield done next weekend. I'll make sure to post pictures once we get that installed, then it'll actually start to look like a boat again!

 

[Watermann]

Looking good and yeah smart move if not comfortable in doing the transom assembly work to have a mechanic do it.

 

[boaterdave90210]

Still haven't heard anything from the marina yet on the bellows. Got out to the barn a few times this week and started digging into the dashboard. I wanted to change out the vinyl on the dashboard - started ripping it apart and found the wood in almost perfect condition. I think I'll sand it down, throw a coat of the helmsman spar on there and call it a day. Really adds some character to it.

My dad made up a lower dashboard for the radio, VHF radio, and switches which I think turned out pretty cool. He even labeled all the wiring on the back which I forgot to take a picture of

Finishing up the windshield too - got a little too late and we ran out of silicone (ended up going with silicone to secure the plexiglass in the channel since most of the clips on the inside were missing). Just have the top pieces and the port side to finish up later this weekend.