1974 21' Chieftain 165 Mercruiser Restoration

[cj8mule]

Margaret Wolfe Hungerford (1878) once wrote that "beauty is in the eye of the beholder". Well, here she is complete with a rotten floor and transom, a crappy paint job, and water in the oil.




I agree she isn't that easy on the eyes, but she'll be seaworthy again by the end of this thread. I promise!

My goal was to purchase a big enough boat to fish the Chesapeake Bay safely with a budget of only $5000. From dry dock to splash time took a little more than 6 months and around $4200 with electronics. I didn't keep track of labor hours, but would estimate them to be around 500.

I would never become a rich man restoring these old boats, but I do gain a lot of pleasure making them useful again. I also gain a dependable boat that I know every square inch of. If something does break out on the water, my chances are pretty good that I can fix it. Or, at least know who to blame. LOL


So, lets get started with some before pictures:




Here's a close up showing the truck bed liner paint the previous owner used for bottem paint. I'd rather deal with wet, fuel soaked pour in foam than have to get this stuff off.








Nice little cabin... even has a sink.




Probably need a complete re-wire, huh?

 

[cj8mule]

This is the original 1974 I6 250ci 165hp mercruiser.


The next photo was taken with just an old phone. No extra quick shutter... the oil / water / sludge was really that thick.



I knew this engine had some problems when I purchased this boat, but that's the worst I've ever seen. Since I'm building on the cheap, I spent the next few weeks on craigs list looking for a suitable replacement donor boat. I found this beauty for $300 and included a very good engine for the Chief!




Time to pull the engine. One thing I've learned over the years is to lable wires, bag bolts and take plenty of pictures before you start pulling engines. Painters blue tape and a permanent marker is great for marking wires and zip lock bags.




Pulling a boat engine isn't that hard, but getting it up and out the boat can be difficult with a large transom. I found it easier to use a chain hoist tied to a suitable tree limb.

 

[cj8mule]

If a picture is worth a thousand words, this next one must be worth a few thousand:



Like I told the Admiral... accidents happen. Luckily, she didn't have any iron skillets on her person. After 30 years of marriage, I know this look says... I'm not happy you just messed up my yard.



It's a little embarassing, but the jeep died on that steep grade and the boat pushed it down the hill. I got it started just in time and turned the wheel. It could've been a lot worse.

A quick tug from the truck and on to the engine removing tree:




Once the engine is out of the boat, I pulled the boat out of the way and lowered the engine into the truck. Then used my engine hoist to pull it out of the truck.

 

[cj8mule]

Getting it all cleaned out and ready to strip some paint. Notice the 2 perpendicular floor stringers inside the cabin? I removed the most forward one so the step down into the cabin has a little more headroom around the bow cap. I'm an older guy and didn't like contortions you have to go through to get out of the bow hatch.


Filled the hull with water to find any leaky rivets. Once repaired, the inside of the hull got the rivets and seams coated with gluvit epoxy.




Paint striping and sanding time with lots of layers of paint. Paint stripper and a pressure washer was the only way that truck bed liner will come off. Have some patience and prepare yourself if your boat needs to be stripped. I have at least 100 hours in this prep.



The cabin top removal only required a few rivets to be drilled out. I screwed the top to a couple of 2X4's which made it easy to move around. The 2X4's also kept the cabin top from racking or bending.



Removed the Chief from the trailor and continued prepping and painting. The empty hull doesn't weigh much and only took a few people to turtle the boat.



Before the Chief can go back on the trailer, I had to weld a new tongue. This trailer was a tilt type, but I felt it would be stronger if I welded it solid.



I drilled some plug holes to weld up and have a solid tongue now.



Going back on the trailor after the trailer got some new rollers, bunk boards, brake lines, tongue, and paint.



The bare aluminum needs a zinc chromate etching primer, and a primer before paint. An acid wash is needed before the etching primer and a light scuff between each coat.



I chose a Rustoleum white primer.

 

[cj8mule]

Rebuilding the bow supports using 3/4" plywood and stainless hardware.



The wood got 2 coats of spar urethane varnish and a coat of Rustoleum primer and paint. Each coat has to be lightly sanded. I used a green scotch brite pad.



Finally, it's time to get some color on her. The blue paint is PPG automotive single stage. The white is Rustoleum Gloss White with hardner and reduced with acetone.



Bow and cabin lids going back on.



New transom is in and floor being installed. The transom and floor recieved 3 coats of spar urethane varnish.



New floatation (pink closed cell insulation board from Home Depot) was installed under the floor. The floor was installed to the aluminum stringers with large flange pop rivets. Backer boards were installed along the seams with 1 1/4" exterior decking screws.

Nautolex vinyl was then installed on the floor.



New storage / seat boxes installed. If you look close, you'll notice the cabin floor is level up the middle which makes it alot easier to access the bow hatch.



Cabin bulkheads and retro dash installed.

 

[cj8mule]

Seat boxes are done. Since I'm on a pretty tight budget, I decided to try sewing marine vinyl.



The engine found it's way home.



Some finishing touches inside.


Doghouse cover, side boards, and back transom doors.


Almost ready for a splash.



And.... splash!!

 

[cj8mule]

I'm not sure if the Chief will ever be finished. After a successful season of fishing, it's time to change a few things to make the Chief better. I've decided to do away with the retro blue vinyl dash and seats. I thought it would be cool to have the interior look like the time period of the boat, but it's time for the disco ball to just go away.

I've also added a custom built rocket launcher.




(Yep, it's snowing... again)






I want to thank iboats and the starmada for their support. This resoration was easier because of this forum and the ones who have gone before.

If you would like to see some more pictures, you can visit here:

http://forums.iboats.com/forum/owner...mercruiser-i-o

Here's a short youtube video of the first splash. I appologize the video is not very good as I was by myself.

https://www.youtube.com/watch?v=8iVZYOPKgEA