1966 Starcraft Sportsman

basstender

Cadet
Joined
Jun 25, 2007
Messages
13
Last Spring, I pulled out my boat, and as usual, the 1980 something johnson 40 that was on it gave me problems starting. It had done this just about every year that I owned the boat, since about 2010. It would be a giant pain to start after being winterized, then it would clear up and run pretty good for the summer. Last year however, The motor fought me, and from late april to June, I tinkered with it almost every weekend. I got busy with other things, and pretty discouraged with the boat. I never ended up getting it running well enough to take it out last year.

Fast forward to December, my 5 year old niece gave me a hand made birthday card with a drawing of us on my boat, and two identical lures, that her dad said she picked out herself. She said they were "for when we go fishing on your boat this summer!"

Now I had a bit of a problem. I decided right then and there that I needed to get my boat working again. And not half-*****ed like last time. I spent some money. I bought a new Tohatsu 50hp 4 stroke outboard.

While I had spent a lot of time 2 years ago, patching a few places in the hull, and repainting the interior, When I took the old motor off, I found that the transom board was rotten. I can't put a brand new outboard on a questionable transom! Out came the splash well, and out came the rotten plywood. Underneath I found a dirty holy corroded mess. Interestingly the corroded parts were just where the plywood was. In addition to corrosion, there were about 40 extra holes from where people mounted who knows what over the years, some of which were badly patched, some not at all.

Stay tuned for more progress.
 

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basstender

Cadet
Joined
Jun 25, 2007
Messages
13
So far I have stripped everything on the transom down, cleaned all the corrosion off, patched the holes using hts 735 aluminum brazing rod, and 3m premium Marine filler on the few holes that were too big to braze. There was one area that was really badly corroded, and when I tried to braze the holes shut, new bigger ones showed up! I cut that area out and rivited a new piece of aluminum behind the old panel, then filled that with the 3m filler.

I got two sheets of marine plywood and fiberglassed them together. Once I cut out the shape of the transom board, I drilled out the mounting holes for the structure of the boat on either side, the mounting holes for the knee, the holes for the outer backer board, and the two drains for the splash well. I then removed the board, re drilled all the holes oversize, and coated the entire outside with the fiberglass resin. Once two coats of that had dried / cured, I used Tyvek tape to Seal one side of the holes, then I filled them completely with the resin as well.
 

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basstender

Cadet
Joined
Jun 25, 2007
Messages
13
While that was drying/curing, (for 72 hrs) I straightened out some warping on the aluminum where I got a little too aggressive with the heat while brazing. Then I coated the outside of the aluminum with primer, and the inside with a solid layer of “coat-it” (similar to gluvit). The picture of the outside primed Looks horrible. It doesnt look that bad in real life. (but it is still pretty bad). I don't really care what it looks like, as long as the transom is water tight and structurally sound!
(The FISH don't care anyway!!!)
I forgot to take pictures of the inside before I put the wood in for good.

Last night, I put the wood in for good, and re drilled my holes for the mounting hardware. I bought all new hex head SS bolts, SS washers, and SS nylock nuts. I put a ring of 3m 5200 around each washer and squirted some in each hole to create a complete seal as I tightened all the bolts holding the transom in.

Tonight, I will be cutting out a new backer board, and coating it with resin. (I totally forgot to cut this out and coat it when I was doing the inner piece). I will be painting the inner piece the same Battleship grey that the rest of the boat interior is, to protect the resin from UV.
Tomorrow, I hope to straighten out the aluminum a bit more, and get the top cap re-installed, and depending how everything looks, I will paint the outer side and the backer board Thursday night.
From there, it should be pretty close to buttoning everything up, putting the splash well back in, and finally getting to INSTALL MY NEW MOTOR!

I have more photos, but I can't upload them
 

Watermann

Starmada Splash of the Year 2014
Joined
Jan 12, 2013
Messages
13,850
Looks like you started the thread after you did all the repairs. Hope it all works out for you. ;)
 

classiccat

"Captain" + Starmada Splash Of The Year 2020
Joined
Dec 20, 2010
Messages
3,412
Look! It's Cassiopeia! :lol:

fetch


You and your niece will be back to fishin' in no time! :thumb:
 
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