1968 15' Starcraft Jet Star Rebuild

[TruckDrivingFool]

Re: 1968 15' Starcraft Jet Star Rebuild

View attachment 107673
Jason, sorry to hear the loss. Now she can look down and lend a helping hand when you launch the jetstar
observe a moment of silence..........................................................................
heres to our loved ones that have left us, and to those who still are here

Well said,

Jas very sorry to hear. My sincerest condolences to your and your family.

 

[proshadetree]

Re: 1968 15' Starcraft Jet Star Rebuild

JA I am sorry dude. Our thoughts and prayers are with you and yours. Have a good weekend my man.

 

[jasoutside]

Re: 1968 15' Starcraft Jet Star Rebuild

Thanks guys. Really, a great group of fellas here on iboats. Big hug for all of ya.

______________________________________________


OK, lets see if I can pick up where I left off. Sleep has found another man to fall on this last week, so, I did manage to pick away at a few things.

I added these brackets, two pair for starboard and two pair for port...

These will eventually be used to hold some rod holders that I'll make out of wood. I should be able to comfortably hold about 8 rods total (maybe only 6). Scroungers note: those were cut out of the Z channel that I pulled from the Islander during demo.

I have been thinking about a medium size casting platform for a while now. I figured I'd have one start right about at the first rib. I figured it would be good use of the space, actually extend my deck a little, make an easy step to get in/out of the boat, and provide a box for anchor/whatnot. So I laid out some lines, liked the black ones best...

Installed alum angle to support the platform..

I sorta zig zagged the rivets which made it much stronger. Also made a couple of relief cuts to help it bend easier.

I wish I could say there was some special scientific way of lining up those brackets. Not so much. I just did some basic measuring, eyeballing and went with my gut. There is really no way for me to know how this boat sits in the water til it's actually sitting in the water ya know. I have a little fudge room to level it out at install, more on that later.

 

[jasoutside]

Re: 1968 15' Starcraft Jet Star Rebuild

I had about a dozen holes in the transom skin that I wanted to seal up. I know we are always trying to figure out ways to make that happen so here is what I did.

I shmeered on a big sploch of JB Weld to the inside...

Then the same on the outside...

It was a two step deal. After the first schmeer it oozed out of the holes just a little bit. So I came back with another layer the next day.

A few days later I just hit the high spots on the inside and sanded smooth on the outside...

The key in my gourde is a good connection between the inside and outside with the JB. Don't know if that is the best method but that is how I ran it. Check back in 10 years and I'll tell ya if it held. I think it will

 

[jasoutside]

Re: 1968 15' Starcraft Jet Star Rebuild

Then I turned my attention back to the transom.

I know we kick around the idea of that OB plate on the back there just about every rebuild that comes around. Here is the direction I decided to go.

1/4" thick 6061 aluminum chunk cut out of that slab I had. I took the time to round the corners so it looked a little more factory...

I notch troweled PL on the backside...

On the transom skin too...

Stainless bolts on the bottom and clamped at the top to keep it in place to cure...

Then I came back, drilled through for the rest of the holes and counter sunk so the carriage bolts will seat nicely...

Little later I'll run a bead of 3M 5200 all the way around the seam. The PL gives a nice comfortable seat and keep water out from behind the plate while the 5200 will make for a water tight seal. Permanent alum plate for the OB, happy with that so far

 

[TruckDrivingFool]

Re: 1968 15' Starcraft Jet Star Rebuild

That plates looks sweet, never have to replace that. I ask out of ignorance is PL not waterproof?

There's a bit of an optical illusion going on did you lay your brackets for the casting deck in roughly parallel to the floor line? Or is there some lean maybe accounting for a stern heavy set up?

 

[jasoutside]

Re: 1968 15' Starcraft Jet Star Rebuild

That plates looks sweet, never have to replace that. I ask out of ignorance is PL not waterproof?

There's a bit of an optical illusion going on did you lay your brackets for the casting deck in roughly parallel to the floor line? Or is there some lean maybe accounting for a stern heavy set up?

Yah, the PL is waterproof. I'm just wanting the tried and true 5200 for the seam. Necessary? Maybe, maybe not. Gives me the warm fuzzy feeling though ya know.

Yah, the brackets are in rough parallel with where the deck will be (very rough since it doesn't even exist yet).

 

[jasoutside]

Re: 1968 15' Starcraft Jet Star Rebuild

Ethan (my youngest) found my Sharpie and "helped" with my layout lines too...

Glad this thing isn't painted yet!

Also got all the holes over drilled in the transom. I duck taped the back side for the fill part...

Mixed up some epoxy and wood flour to about the consistency of really thick gravy...

Filled the holes...

Let it cure for a couple of days, pulled the tape and sanded everything smooth.

 

[jasoutside]

Re: 1968 15' Starcraft Jet Star Rebuild

I got the topsides all prepped to paint too. I started with 120 then 220 on the sander. I finished with this sanding pad by hand...

I went after that trim rail at the front of the splashwell too. I'm after the brushed alum look rather than the polished chrome look...

Besides, I can't seem to figure out this whole polishing thing. Tried a few times and just can't seem to get it.

Then I installed the rubrails back on. Rather than going with those super long nuts/bolts I grabbed these 1 1/4" rivets, much easier to install...

Then I worked on em a little.

Before...

After...

I started with 120 on the belt sander, then 220, 320, 400 all by hand then finished with these metal sanding pads...

Lot of elbow grease but I am happy with how they turned out.

 

[Jayb123]

Re: 1968 15' Starcraft Jet Star Rebuild

Yeaaaah ...Jason the rub rail... looks great..... I agree, I havent really been able to get the alum to polish too. I was actually kind of afraid to hit the alum with heavier grit. Now that I see you started with 120... Im gonna go back to the drawing board on mine and start there and see where that leads me. I think the brushed "look" .... looks better also IMO. .

 

[Teamster]

Re: 1968 15' Starcraft Jet Star Rebuild

Lot's of metal polish stuff available here,...

http://www.iowa80.com/DirectionsWEB/webcart_category3.php?catid=CLEANING&catPage=2

Some truck owners like to keep things shinny,...

Heck yous might even find some chrome goodies and lights for your projects in there,....

 

[TruckDrivingFool]

Re: 1968 15' Starcraft Jet Star Rebuild

Thanks for the "warm fuzzy" explanation.

You've been busy. The trim cleaned up nicely now your going to have to be extra careful painting.

 

[Bwana Don]

Re: 1968 15' Starcraft Jet Star Rebuild

Just read about your Mom. My prayers go out to your family. So sorry bud.

 

[third times the charm]

Re: 1968 15' Starcraft Jet Star Rebuild

I think you'll have her out in no time. the metal work is looking good. As far as the front and how it sits in the water, I know my holiday sat a little angled but not that much even with the weight of a i/o.( by the way guys, this is while the boat was dry not half full of water lol)So i imagine keeping close to parallel with the floor you should be alright. Love the layout lines from your son I dont know why you didnt follow his marks lol

 

[jasoutside]

Re: 1968 15' Starcraft Jet Star Rebuild

Yeaaaah ...Jason the rub rail... looks great..... I agree, I havent really been able to get the alum to polish too. I was actually kind of afraid to hit the alum with heavier grit. Now that I see you started with 120... Im gonna go back to the drawing board on mine and start there and see where that leads me. I think the brushed "look" .... looks better also IMO. .

Here is the thing Jay, just a heads up - I think the second you touch a piece of sand paper to that aluminum you are destined for the "brushed" look. I'm not so sure you can bring it back to that chrome sort of finish after doing so. I really like the brushed look so I am cool with the idea. I have tried random orbital sanders on that stuff and it doesn't work very well at all, kinda chews up the alum. The belt sander runs with the "grain" of the alum (sort of) so it works much better. The 120 grit works well cutting through 40 years of grime, dirt, scratches and small dents. The rest of the process is just elbow grease, a lot of it.

Thanks for the "warm fuzzy" explanation.

You've been busy. The trim cleaned up nicely now your going to have to be extra careful painting.

Yah, you know, what makes ya sleep well at night sort of stuff.

Yup, a good tape job will help protect that pretty trim. I'll also hit it lightly one more time with the sanding sponge, lacquer thinner, then Shark Hide for long term protection.

I think you'll have her out in no time. the metal work is looking good. As far as the front and how it sits in the water, I know my holiday sat a little angled but not that much even with the weight of a i/o.( by the way guys, this is while the boat was dry not half full of water lol)So i imagine keeping close to parallel with the floor you should be alright. Love the layout lines from your son I dont know why you didnt follow his marks lol

Yah, boats seem to sit a lil differently when they are half full of water eh buddy? Ah well, that's what buckets are for

Yup, he saw me drawing on the boat so he was just looking to be helpful. Love that little guy!

 

[jasoutside]

Re: 1968 15' Starcraft Jet Star Rebuild

Scraped the MC numbers off...

Goo B Gone will get the rest of the adhesive off in a snap.

Then it was time to pay attention to the bottom side of the hull. I hung it in the Keeper strap and spun it over...

Set it on some sawhorses...

Here is was I am seeing...

Really weird. It's like it been painted over and kinda peeling off in some areas. But I can't say for certain that it has been. I don't see brush strokes or a paint line or anything. I wonder if it was sitting in the water for a long time and the first layer of factory paint is coming off some? Dunno?

 

[jasoutside]

Re: 1968 15' Starcraft Jet Star Rebuild

Couple of rivets that seem to really like one another...

Bad spot of dock rash...

All in all not real bad. Not even close to what some of you guys are dealing with!

I had some of this sitting in the shop...

So I gave it a spot test...

You can see at the upper right hand side of that spot where I used a scotch bright pad to scrub the paint away. I just barely touched the hull with it and you can see it just dulled that shiny chromey look.

Dumped some more on...

A plastic scraper works ok, kind of a pain around the rivets. It is easy to see that the tool of choice would be a power washer or at least a garden hose to rinse after the stripper lifts the paint. My problem? I just don't feel very good about rinsing a few gallons of stripper over where I pull my drinking water.

I'd like to go the stripper route on this hull. At least the bottom anyway. The side hull paint is sound. I don't think a tarp under neath would hold all the water/chemical coming off the boat if I was rinsing.

I think I have two options. Use scrapers, paper towels and such. Kind of a pain and tough to come clean in the tight spots at the rivets/keel. Or, haul it somewhere away from a water well and complete the job. Maybe Dad's house.

Anyway, that is where I am at for now.

Have a good Sunday guys.

 

[dozerII]

Re: 1968 15' Starcraft Jet Star Rebuild

Hey Jason, the bottom of the hull looks in real good shape. Kind of wierd how that paint went. That is the problem with paint stripper, how to catch the bad stuff.
Glen

 

[Jayb123]

Re: 1968 15' Starcraft Jet Star Rebuild

Hey Jason.... After using some stripper on part of my hull. I used a smaller softer/brass wire brush with stipper. It really got the paint off the rivets, rivet edges and the crevices real nice . An old tooth brush was a little soft.

 

[jasoutside]

Re: 1968 15' Starcraft Jet Star Rebuild

Hey Jason, the bottom of the hull looks in real good shape. Kind of wierd how that paint went. That is the problem with paint stripper, how to catch the bad stuff.
Glen

Yah, I'd rather not go with sanding due to the paint condition and all the dust. On the other hand I'd need to figure out how to handle all the chemicals coming off the boat if I went with the stripper. Ah, I'll figure it out in the next day or so.

Hey Jason.... After using some stripper on part of my hull. I used a smaller softer/brass wire brush with stipper. It really got the paint off the rivets, rivet edges and the crevices real nice . An old tooth brush was a little soft.

I am with ya Jay. That ^^^ was actually just rolling around in the brain box there. I think I may give that a shot. Maybe just use some water in a bucket to rinse a little in the garage, sweep up/clean up whats left on the floor. I may be ok going that route.

Thanks for chipping in guys!