1982 Sylvan Bassboat project

[craigweaver]

Re: 1982 Sylvan Bassboat project

Judge, only you know what is safe for your son to be involved with, I don't call that over protective just being a thoughtful parent.

WOG, tonight we popped the cap!! What a process that was. It is heavier than I thought it would be. I used a come along to winch it up to the height I wanted and tied it off. I was able to get the Teleflex disconnected and the throttle removed( I know that's not what it's called but I'm drawing a blank right now.) the wiring is an absolute rats nest and I'll be re-wiring pretty much the entire boat. I left as much connected as I could and coiled the wiring up on top of the console to sort out later. Next step is to finish cleaning the crap out and order our tyvek suits, respirators and goggles on Thursday.

I did get lucky on one front tonight. I didn't even think about the garage door when I was hoisting and tieing off the cap. I happened to notice it was going to be close only AFTER I had everything where I wanted it. I nervously opened the garage door to find I had about a foot of clearance, woohoo! I surely didn't want to have to move my rafter bracing and hook. Ok, on to
the pics from tonight. Questions coming soon I am sure

The cap in its storage position.

 

[Decker83]

Re: 1982 Sylvan Bassboat project

Looks good.

Doing a great job with the cap. Don't bump your head. (lol)

Now you can get to the nitty gritty with the cap out of the way.

Good luck and keep on posting the pics.

Kent

 

[bear_69cuda]

Re: 1982 Sylvan Bassboat project

Awesome Craig!

now fer some grindin grindin grindin!

 

[craigweaver]

Re: 1982 Sylvan Bassboat project

Thanks Bear & Kent! You guys are right now it's time for some grindin, grindin, gindinl... lol

Kent, I thought about the cap being in the way but I don't have much room to put it and I'm not putting it outside for the winter. So a few banged heads beats more weather cracks to fix.

Tonight I got the rest of the foam & carpet out and am pretty much ready to start cuttin and grindin. Just gotta wait for the respirator, tyvek suits and goggles to arrive. Oh well, with Christmas here I guess it's a good time to take a few days off and spend time with the rest of the family, lol.

Merry Christmas all. Talk with you next week.

 

[JDA1975]

Re: 1982 Sylvan Bassboat project

Kent, I thought about the cap being in the way but I don't have much room to put it and I'm not putting it outside for the winter. So a few banged heads beats more weather cracks to fix.

the boats on rolling cradle, so just move it over some to work and no head bangs needed!

 

[Woodonglass]

Re: 1982 Sylvan Bassboat project

Nice!!!!! Make sure and take Plenty of PICS!!!!! Especially of the wiring "Rats Nest"!!! Ask me how I know That will come in handy

 

[Decker83]

Re: 1982 Sylvan Bassboat project

Wish I had a garage to hang my cap in. I would bump my head all day long to have a garage to work in.

That is a good ideal to leave the cap inside like it is. There is enough work without adding more.

Looking good.

Kent

 

[craigweaver]

Judge, you are correct! I can roll it out in the middle of the garage to work on it.

WOG, I'm right there with ya bro! Although I think an entire rewire will be required. It was/is awful!

Kent, I gave up my spot in the garage this winter for this project. Well worth it. FYI, I had to wrench in the drive for years before I had a garage, so it can happen.

 

[JDA1975]

Re: 1982 Sylvan Bassboat project

I got garage envy...In Arkansas garages are rare, unless you live in a bigger city, and working in a carport sucks! I was going to try and just fix my wiring originally but heck 30 years of noticeably unprofessional alterations, left me even more confused than I already am...luckily the control unit wires that connect to outboard were untouched so reinstalling tat should be as easy as removing it was, but starting from scratch and adding 1 circuit at a time just seems easier than trying to find and repair shorts... looks like you are thinking same

 

[GT1000000]

Re: 1982 Sylvan Bassboat project

I got garage envy...and working in a carport sucks!

I have garage and carport envy...

Hey CW,

Have a very Merry Christmas and a safe, happy, and prosperous New Year.

 

[Decker83]

Re: 1982 Sylvan Bassboat project

Kent, I gave up my spot in the garage this winter for this project. Well worth it. FYI, I had to wrench in the drive for years before I had a garage, so it can happen.

I have a 2 car garage but it is full of welding equipment and a large 16 ga hand break amongst other stuff I have collected over the last 30 years.

Even if I did clear everything out my boat will not fit in the garage so I have to work outside under the tent.

Have a Merry Christmas and a Happy New Year.

Kent

 

[craigweaver]

Re: 1982 Sylvan Bassboat project

Yup Judge, we're doing it exactly the same with the electrical. Just as well, as anal as I am I'll know everything I can't see is done right and I'll be able to sleep at night, lol.

I ordered our Tyvek suits, half face respirators with replaceable cartridges and goggles last night. Planning a quick trip to Harbor freight before they arrive to get a cheap grinder. I have all next week off so as soon as the safety equipment is here I plan on starting the grinding & cutting. I also had a brilliant idea to use the hanging cap as a frame to hang plastic sheeting from/around and make a clean room to try and keep the dust in the rest of the garage to a minimum. I also plan using the shop vac with drywall filter to try and suck up the grindings as we go since there's 2 of us.

Merry Christmas to you as well GT1k and Kent! And to everyone else as well. I can't wait to read everyone else posts about their new boat refurb toys they get for Christmas. I got an Ipad so there won't be anything else this year but that was all I wanted.

Catch ya all after Christmas!

 

[Decker83]

Re: 1982 Sylvan Bassboat project

I also had a brilliant idea to use the hanging cap as a frame to hang plastic sheeting from/around and make a clean room to try and keep the dust in the rest of the garage to a minimum.

That is a great ideal. I have fiberglass dust all over my back yard. There is a ton of dust from all the grinding.

 

[craigweaver]

Re: 1982 Sylvan Bassboat project

Well, with the holiday festivities over I was able to spend a little time on the boat today. I was able to get most of the main floor out and about a hundred pounds of soaking wet foam. I can't believe how much water that stuff holds!

Before ....

After....

Also a quick question. Are the built out areas on the sides, shown in the next 2 pics, the flotation boxes? Should I remove and rebuild them or can I leave them out to gain some more space?

 

[JDA1975]

Re: 1982 Sylvan Bassboat project

those side boxes are foam filled...your boat weighs X pounds and requires X amount of foam to float it....they add it where they can get away with it, and use more aft than forward to keep it from swamping motor down. I removed mine, when doing tear down because the decking went underneath them, but they were in a different position, yours are long and skinny so you may be able to slide deck in under them. I would check the foam is dry (mine was) and if so see if you can leave them intact. as far as doing away with them, for safety I wouldn't! They also provide some structural support, as has been said to me...areas that are foamed are normally thinner glass because they plan on the foam to provide crush resistance

 

[Decker83]

Re: 1982 Sylvan Bassboat project

Keep up the good work. Your making progress.

The build out on the sides may only be for foam. But they may also be for support.

You can cut them out and reuse them, but I would find out if they or for support before I left them out.

Have a great New Year

 

[craigweaver]

Thanks for the responses Judge and Decker. We'll be at least cutting them out carefully after the sides of the cradle are built to keep the hull from flexing. From what we have found so far it's all been sopping wet foam. So far we've removed a few hundred lbs worth in just the main deck area alone!

Tonight we finally had a few hours for me and the first mate to get back at it. First we opened and assembled our new safety gear. Here's a pics of dad Vader and his first mate.

I also taught him how I figured out to get the foam out last week while he was gone. (thus the smaller progress over the holidays) Now I'll share my trick as I see everyone has their demons with this, lol

First it looked like some blown in fiberglass stand was over all the stringers and cross bracing tying the foam to them. I used a cutting wheel on the 4.5" grinder to cut through this inside all the boxes of foam formed by the stringers and cross bracing. Next I took a fairly stiff putty knife and was able to push it down in the grinder cut until I felt the hull and repeated the process until I had gone around all sides tied to something.

Then I used a flat bar and hammer claw to pry the entire section out in as few a pieces as possible.

---- continued in next post.

 

[craigweaver]

This is one of the cleaner sections we removed all in one piece.

Then we could easily use the putty knife to clean up the remaining foam along the stringers.

And usually this was all the leftovers we had to clean up!

By the time we were done tonight we had all the foam out of the main deck area. Still need to clean out under the cross braces but the worst of it is gone.

Finally looking like we're making progress here, lol

Next up is to add sides to the cradle. I'm a bit worried about the hull flexing out when I cut out the front deck and side boxes.

Happy New Year all! It's gonna be a great year working on our boats.

 

[Woodonglass]

Re: 1982 Sylvan Bassboat project

Couple of things. Use Baby Powder on your faces to keep the itching off. Two, get some nylon straps and strap your hull to keep it from flexing. You really got a lot done. Good Job.

 

[JDA1975]

Re: 1982 Sylvan Bassboat project

where were you when I removed my foam...man that looked like it was a lot easier and a lot less clean up then my messy route! Nice job on that...another option for the dust is to wear a painters hood, completely covers the face where the respirator doesn't...don't put respirator over the cloth though..put on respirator and goggles first then the hood and pull the hole over the mask