1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

[1lrover1]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Looks great!! Doing a similar boat (Mr. Crabs thread) and was hoping I might be able to get some assistance on the rear section dimensions etc.. Also, when you did the stringers, did you grind all the way to the hull or did you leave any of the glass that was there. I mean the glass that encapsulates the stringers on mine is in great shape and I hate to cut that away. Rather I was hoping to remove the rotted stringers leaving much of the glass there and 'peanut butter' / bed the new stringers in then 1708 around things to the hull. Likewise doing the same to tie into the transom. But, I don't have a clue what is the right way to do this. Anyway, I'm learning lots from your thread, very nice work. Thanks!!
Rob

 

[Nickypoo]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Hi Rob,

Thank you!

The "right way" to do it is to completely grind down the old stringers to the hull and completely start over.

This is not the way I did it. This is one of the things I was referring to when I said that some things I did would make someone more experienced scream bloody murder.

I'll tell you how I did it, but just know that this isn't the ideal approach. What I did is exactly what you described, I cut the fiberglass around the stringers about halfway down and popped the cap off. I then scooped/chiseled/vacuumed the remaining wood out of the cavity. Then I squirted some 5200 along the bottom and epoxied the new stringers in.

When I wrapped the top of the stringers over with fiberglass, there was that awkward ledge where the old fiberglass had been cut. This leaves a gap where the new fiberglass lifts off the stringer when it encounters that ledge. I let it cure that way then I went back through with a syringe and filled any empty spaces up with resin. The end result is pretty solid in my opinion but like I said, this isn't the recommended way to do it.

I could post some more detailed pictures if you'd like.

Oh, and I could send you my drawing files that contain all the dimensions. You can download DWG True view (free) from Autodesk that will allow you to view them.

 

[1lrover1]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Thanks for the help!* Whatever stuff you could send me is greatly appreciated on the dimensions, my email is below.* I don't really see anything wrong with that approach on the stringers.* I wanted to avoid grinding things down for two reasons.* First, seems like the glass that is there is in good shape with a nice bond to the hull and second, I don't want to run the risk of creating hard spots if not spaced correctly given my novice glassing skills.* I'm not trying to avoid work, but I don't feel entirely comfortable cutting away everything.* I'm much more confident that I can do the decks/ foam and everything else reasonably well.* But the stringers and transom..well let's just say I was reallllllly hoping I could have avoided messing with them.*
*
Looking forward to seeing your splash day pics..doesn't seem you are too far away at this point.
*
Thanks again,
Rob
barenjager911@gmail.com
*

 

[Nickypoo]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Thanks for the help!* Whatever stuff you could send me is greatly appreciated on the dimensions, my email is below.* I don't really see anything wrong with that approach on the stringers.* I wanted to avoid grinding things down for two reasons.* First, seems like the glass that is there is in good shape with a nice bond to the hull and second, I don't want to run the risk of creating hard spots if not spaced correctly given my novice glassing skills.* I'm not trying to avoid work, but I don't feel entirely comfortable cutting away everything.* I'm much more confident that I can do the decks/ foam and everything else reasonably well.* But the stringers and transom..well let's just say I was reallllllly hoping I could have avoided messing with them.*
*
Looking forward to seeing your splash day pics..doesn't seem you are too far away at this point.
*
Thanks again,
Rob
barenjager911@gmail.com
*

I completely sympathize with the stringers and transom. Actually the transom wasn't so bad, but the stringers stressed me out. I didn't really have the fiberglassing skills or knowledge to do it the "right" way at that point so that's why I left the open channels to fit the new stringers in. Maybe next time I'll be more comfortable doing it the other way.

Anyway, glad to help. Tomorrow when I'm on my computer I'll email you the CAD files. I'll probably post them on here if I can too.

 

[Nickypoo]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Ok, I'm posting the PDF files of my rear structure.

If you use them it would be a good idea to measure your boat because the floor may be at a different level or the cutout for the gas tank may be different.

Also, I had to trim the top after it was all built and sat in there so it was flush with the top of the cap in the boat (Piece 1).

I also had to trim the curve around the hull on the sides slightly (Pieces L3 and R3).

The back ended up not meshing well with the transom. It sat like a half inch from the transom and I just started fiberglassing the sides. I'm going to then fill the remaining cavity with resin from the top (Pieces L2 and R2).

View attachment Boat Rear Structure 3D.pdfView attachment Boat Rear Structure 3D Hidden.pdfView attachment Boat Rear Structure Layout Detail 1.pdfView attachment Boat Rear Structure Layout Detail 2.pdfView attachment Boat Rear Structure Layout Detail 3.pdf

I'll post the rest a little later. Sorry if my dimensions are a little confusing.

 

[Nickypoo]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Another 5:

View attachment Boat Rear Structure Layout Detail 4.pdfView attachment Boat Rear Structure Layout Detail 5.pdfView attachment Boat Rear Structure Layout Detail 6.pdfView attachment Boat Rear Structure Layout Detail 7.pdfView attachment Boat Rear Structure Layout Detail 8.pdf

 

[Nickypoo]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

And the last two:

View attachment Boat Rear Structure Layout Detail 9.pdfView attachment Boat Rear Structure Plywood Layout No Title Block.pdf

The last one is the layout for cutting out of a plywood sheet. Everything can come out of one 4' x 8' sheet of plywood, you just have to be careful to not overextend the cut into another piece. I laid out all the pieces in pencil before I even cut anything so I could see where exactly I was cutting.

Another note: You will notice that the cut angles go to the 4th decimal place or something ridiculous. Obviously your circular saw can't cut 7.1045 degrees precisely . I used a plastic angle gauge that was still somewhat imprecise but it got me closer to the right angle than using the markings on my saw, which are incremented at 5 degrees.

On the same idea are measurements such as 59/64". Measurements like these can just be approximated. 59/64" becomes 15/16", etc...

I made extensive use of clamping down a straightedge as a guide.

I can't post the .dwg files here.

 

[1lrover1]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

This is great! Lots of valuable info shared here. Should sticky this thread as it covers what most of us fear, deny, then confirm and finally confront with that 'new' boat we just dragged home. This is really nice work. Many thanks for sharing all of this. Likewise to iboats for providing the resource.

 

[at1oliver]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

I've been reviewing your rebuild thread and have the same boat which I believe will require all if not more work than yours, anyway your's is an inspiration.

Was curious to know if your trailer has regular bunks or rollers? Do you know if your hull acquired any warpage when you removed the old stringers? There are posts on other builds that warn against warping if done on a trailer without the proper support.

 

[Nickypoo]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Hi at1oliver, thanks for the kind words.

Yes, you are right in that the hull should be properly supported while it's gutted. I however did it kind of fast and loose. The one thing I kept tabs on throughout the whole process is the alignment of the windshield. I used a large ratchet strap wrapped around the entire hull to keep it from flopping open. Other than that, the hull seemed stiff enough on its own. Of course, this assessment is far from scientific.

The end result is close as far as windshield alignment. I am unable to tell if the actual shape of the hull changed. If it did, it probably wasn't by much.

The trailer is a roller trailer. Not quite the best platform to rebuild a boat on. In fact, a couple times the empty hull almost flipped over on me as I was reaching over the side with something heavy.

Anyway, the whole project is in hibernation as we are heading into winter and I am busy with school. I actually made a lot of progress that I haven't posted here before I stopped working on it. I anticipate the maiden voyage sometime early summer.

 

[thndrmech]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Hey Nick,
Great Job on the Resto! One question. How hard was it to pull the engine. I am in the process of getting my 84 bayliner 1950 with the same set up running, but I believe there may be either internal problems, or transmission problems. wanted to separate everything and take a look, but needeed to know how difficult it was to yank that sucker.

 

[mfsb]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

just saw your thread for the first time. I picked up a great 85 cuddy 1950. Yeah it is a bayliner, but it is mine and anyone who judges me as less than them for owning a bayliner can **** off... I get a little sensitive about being snubbed, sorry! I love my boat it is fun and everyone should enjoy being on the water! If you have a fun project live it up!

Your boat is lookin great! I have the same aq125/270. Mine is all corroded from living in saltwater, however it shifts and runs great, just stiff to turn I need to pull it and redo the the pivot, I have isolated it to there. Yours being a fresh water I wouldn't imagine it has the same problems. Good luck with the floor, your for thought with the CAD is impressive and your stringer system looks awesome!

 

[Flycraft]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Just wanted to say thanks for all the great pictures and diagrams on your project!! I just picked up a 1982 bayliner capri bowrider 2150 with a aq125a/270 and it too needs a full refit inside. Your post have been a lot of help. Thanks!!!

 

[Nickypoo]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Hey everyone, thanks for the replies . I've been pretty busy with school so I haven't posted here at all. Boat's still kind of on the back burner, but I've got some progress I would like to share in following posts.

thndrmech: It's not too difficult if you have a proper hoist setup that you can lift the engine with. Other than that, the biggest obstacle is corrosion. There are some tight tolerances on this unit and if there is any kind of substantial corrosion on the aluminum then pieces get locked together like they were welded. Keep a torch at hand for sure. If you dig in then you may find you will need to replace a lot of things, mostly just little rubber o-rings and seals, stuff like that.


mfsb: Unfortunately mine too has been ran in salt water when it was used. Almost everything aluminum was corroded together, but I'm working everything free as I go. At this point there's not too much more that can be corroded, since I've gone through most of it.


Flycraft: Good luck with your project! I'm glad to know that my posts are of use to other people. I'll try to keep the updates coming as I start to work on it again closer to summer.


Again thank you all for being so supportive.

 

[Nickypoo]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Ok, so I'm sorry for leaving my thread off in kind of a sorry state :lol:. Major cliff hanger there with just the interior pieces. I did get a lot more finished at the end of the summer than I posted here, and a little bit last month too.


First of all, I got all those interior pieces fiberglassed in and seat based filled with new foam:

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Also got the ski locker hole cut:

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Yes, it was looking like a gross mess at this point. It's hard to keep dirt off of sticky fiberglass. Please pardon my clutter.

 

[Nickypoo]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Here is the crappiest part of restoring this boat: sanding fiberglass. Especially when you live in a neighborhood and are doing this on a hot sunny day.

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I tried to get some ventilation going in there with a fan and a dust collector but it was just hell on a trailer :mad-new:.


Anyway, after I sanded everything down we got a gallon of bilgekote. That stuff does not go very far. I figured I could paint the whole boat with a gallon. I ended up only getting the front and bilge done. What's done looks ok, paint is spread pretty thin to get the most coverage I could. I'll probably get a little more later on and come back to the thin spots and spots I missed.

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Next with the transom plate and powdercoated steering bracket:

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[Nickypoo]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Next was my favorite part so far... dropping the engine in! My cousin was down from Minnesota, so I had some extra hands for a few days.

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You may be thinking that my hoist beam thing looks a little sketched out. You're probably right.


Well at any rate we got it in there...

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Freehanging from the transom at last:

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Here I composed a little comparison image showing the before and after of the bilge area:

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[Nickypoo]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Some more before/after pictures.

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I used some buffing/polishing compound on the control panel, and then clear coated it with some spray paint. Got all new switches. I also sandblasted the center of the steering wheel and spray painted that black. New gauges may be in line at some point, since a couple of them don't even work.

​

 

[Nickypoo]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

I replaced the corroded engine harness connector with a new Deutsch connector from Summit racing. I thought it was a great solution. I didn't really find a suitable or reasonably priced replacement anywhere else.

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Here is a little video of the engine starting and running in the boat after we installed it. My phone falls off the dash almost immediately but if you keep listening the engine sounds pretty good. That tapping/rattling noise is something on the dash. It's not the engine.

I noticed while the engine was running that the impeller was not sucking up water from the tub of water the outdrive was sitting in! Figured out from doing a little investigating and reading on here that the seals on the water tube were shot. If I bypassed that particular portion of the water circuit then the impeller would suck up water just fine. This led me to tearing apart the outdrive. Now it looks like this :facepalm::lol::

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I just decided to repaint/reseal the whole thing, and replace some parts while I'm in there. Disassembly was... difficult. The clamp ring on the upper unit was rust-welded on. I had to bang on it with a hammer and torch it for two days. Anyway, the whole thing is torn down. Shims and seal were cataloged and organized. We shall see how the rest of it goes.

I was hoping to get the boat in the water while my cousin was here, but since the outdrive wasn't picking up water, and we're slacking on the registration issue with our neighbor, we weren't able to take it out :grumpy:.

That pretty much brings everything on the project up to speed here.

 

[rykersdad1]

Re: 1984 Bayliner Capr 1950i, Volvo Penta AQ125A Resto

Awesome Thread i am currently redoing my '85 bay liner capri and the whole rear section is my worst most rotted area. those pdf files are great. i feel like i should have paid for them i am by far no carpenter or architect or anything like that but i am gonna try to get my rear jump seats and engine compartment to begin to look that good. I do a good deal of mechanic work and i would have recommended the new bearings in the motor as well but if it works it works. Thanks for the thread i will be keeping an eye on any new progress. any plans on a sound system of any kind? if so just curious have you thought of any speaker locations.