1985 Conroy X-19 I/O Transom Restoration

[nrasnake]

Re: 1985 Conroy X-19 I/O Transom Restoration

Back to the fiberglass! The new manifold and elbow on their way and all the outdrive and gimbal parts are on the shelf.
I've been thinking about how I'm going to flatten the hull around the transom since I didn't use enough 2x4 clamps and the resin kicked much faster than I expected last fall.

This what it looks like:
It is within spec (<1/16") from port to starboard (horizontal) and well out of spec (0.1" max) from top to bottom (vertical). There is a high spot at both upper transom plate through holes. The overall thickness varies of course, but is between 2.17"-2.29". So, it is too thick (>2.25") at the high spots.

-----------------------------------------------------------------------------------
My plan is to shoot for a final thickness of 2.21" by grinding down the high spots (approximately -0.08") and filling the low spots with one layer of CSM (+0.03"). This should put the overall thickness to within 2.20"-2.21" and allow for a final layer of gelcoat. I can take a little bit more off of the inside transom surface to stay below 2.25" thickness if needed in the end. Obviously, I won't be able to control everything to 0.01", but this is for planning purposes.

Do you guys think this work?

1. Take the gelcoat off (down to the hull fiberglass) inside the blue oval shown (feather at the line).
2. Grind down the hull fiberglass at the high spots by the amounts shown in the orange and red ovals (feather at the line).
3. Put a patch of CSM in the green ovals.
4. Peanut butter around the edges of the CSM patches to feather the edges in.
5. Grind the edges of the CSM/PeanutButter smooth.
6. Block sand the entire surface inside the blue oval to reach the final flatness desired.
7. Gelcoat the entire surface inside the blue oval and feather onto existing gelcoat.
8. Block sand the entire transom surface.

My biggest concerns are with adding the CSM/PeanutButter as a filler, but I don't know what else would work and still be structurally sound. I've also never used gelcoat, so I'm not sure what to expect. Any suggestions or ideas would be much appreciated. I think it's all down hill from here if I can get this straightened out.

Thanks!!!

 

[nrasnake]

Re: 1985 Conroy X-19 I/O Transom Restoration

After doing some further research, it looks like my plan is the correct fix for the most part. The one difference I've seen is that rather than using a peanut butter mix on the edges of CSM, I should use a cabosil+polyresin mix (peanut butter without the chop strand). This would be considered a skim coat to fill in any edge transitions, sanding marks, and pinholes. I think I will also need to account for about 0.02" for the gelcoat thickness. Appreciate any advice on this.
Thanks!

 

[GT1000000]

Re: 1985 Conroy X-19 I/O Transom Restoration

Your plan is sound...the polyresin and cabosil should work just fine, since you will be applying a compressive load on it...
When sanding, use a dead flat long board with 36-40 grit, then work your way up 120 grit...a lot of work, but definitely necessary.
If you have access to an air file and a compressor to run it, the job can go much quicker...
The 120 grit will leave the surface ready for a final application of gel coat...
Keep in mind the normal thickness of gel coat is about the thickness of a penny, if you gel both the inside and outside, that can add up...so you might want to reduce the surface a little more before filling to compensate.
Looking forward to the outcome.
Best of Luck,
Gus

 

[nrasnake]

Re: 1985 Conroy X-19 I/O Transom Restoration

Quick update. Not quite done yet, but getting there. So far I've gotten the high spots ground down, the CSM patches installed followed by a thorough block sanding to get everything very close to flat. I also block sanded the inner transom surface. That left me with a consistent 2.19" all the way around. Now, I've gotten the second (and hopefully final) skim coat of poly resin+cabosil+pinch of chop strands which should be enough to leave a perfectly smooth surface for the gel coat, after a final block sanding with 120 grit.

A question regarding the gel coat. I purchased a pint of white gel coat without wax and bought the wax additive separate. I plan on putting down two coats with a foam roller and adding the wax to the last coat of course. I didn't buy any pigments because I was guessing the current coat is just white, but based on the fiberglass dust I've wiped off after grinding, I'm thinking the coat is more like a light grey. However, it could be because the current coat is oxidized since it hasn't been cleaned or waxed in 3-5 years. Based on the images (you can see the fiberglass dust and along the edges where I sanded off the oxidization), do you think I will need any pigment added? If so, just some black or another color? And do I need to buy "gel coat pigment" or is there another alternative? I do plan on coating a test piece first to compare colors.

Initial gel coat removal:

First CSM filler layer:

Roughly sanded:

Block sanded and marked for final high and low spot adjustments needed:

Final skim coat:

 

[nrasnake]

Re: 1985 Conroy X-19 I/O Transom Restoration

Thought I'd give an update since I've not posted in awhile. I've still been plugging away... slowly but surely!
Transom is ready for the gelcoat:

[/URL][/IMG]

[/URL][/IMG]

My pure white gelcoat is not going to match. A local paint supply suggested they could match the hull color with Urethane paint. I'm planning to gelcoat the area, overlapping the edges some, and block sanding/feather it in, then have the entire sunk in portion of the transom painted.

[/URL][/IMG]


I'm also about finished with getting the fuel tank and deck put back in. Hopefully all fiberglassing will be DONE soon. Hit a snag with the passenger seat box realizing the back panel was rotted. I had to replace the rotted wood and fiberglass that in as well. The fuel tank has taken A LOT more work than I planned. Originally it was just resting on a 4 inch wide piece of plywood fiberglass to the bottom of the hull. I assume that was original, but I didn't feel good about putting it back that way. So, after lots of measuring and trial and error I made wood supports near the stringers to hold the tank off of the hull (picture doesn't show it, but they are are all fiberglassed with CSM now). Everything fits perfect and now there's plenty of room for air circulation and water drainage under the tank. I also fiberglassed in some deck supports along the stringers to avoid having to screw a furring strip onto to the stringer. This should last much longer and avoid any leak paths.

I also adhered some aluminum patches to the tank where it will rest on the wood supports to prolong any wear damage over the years. I used PL polyurethane flashing/roof sealant which adhered great and has plenty of flex to it once dried. Hopefully it will last and not crack over time. Note, I did try PL premium adhesive first and it did not stick AT ALL even though I prepped it the best I could. In disgust, I tore it all off and started fresh with the flashing sealant.

Oh, and I found a roll of thick plastic mesh at the hardware store that's used for keeping leaves out of gutters (for about $4). It made a nice screen guard for the bulkhead drain to prevent debris from getting in the fuel tank bay from the ski locker area.

More to come!

 

[GT1000000]

Re: 1985 Conroy X-19 I/O Transom Restoration

Nice job on getting the transom flat!
The rest of the progress looks great...I like the screen idea to keep debris out.
There are gel coat color matching kits available that you can use to get a very good match in color...

 

[nrasnake]

Re: 1985 Conroy X-19 I/O Transom Restoration

Quick update. Should be done with fiberglass and paint tomorrow. Lots of good progress just in time for the cold weather.
Fuel tank is in. Deck is on. Final coat of resin on deck, seat boxes, and engine compartment. Engine compartment boxes are foamed and sealed. Keyhold is gelcoated. Bilge pump is mounted. Battery tray and trim pump platform are fiberglassed in (more pictures soon).







I first rolled one two coats of gel with a foam roller and the results were much less than pleasing. So, I sanded everything smooth with an orbital sander and 120 grit and sprayed a final gel coat with a $6 disposable aerosol sprayer. I still got some orange peel, but I'm pleased. I will probably do a light 600 grit wet sand and polish to finalize it. The white to grey is definitely noticeable, but I think it will work. I can always paint it later... maybe paint the entire boat .

[/URL][/IMG]



Oh, and the PL polyurethane flashing adhesive I put on the fuel tank has fully cured and it adhered perfect. It is super strong, very flexible, and sticks great. Assuming it lasts, I would highly recommend this stuff for any sealing or cushioning... great stuff. On the other hand, PL Premium adhesive WILL NOT stick to aluminum. Still awesome glue, but it seems best for porous materials like wood.

Engine compartment gets Interlux Bilgekote tomorrow. Hope it goes on without trouble. More pics to come.

 

[nrasnake]

Re: 1985 Conroy X-19 I/O Transom Restoration

First coat is on. Really like the Bilgkote paint... highly recommended. I still have 1/3 quart left which will be plenty for a second and maybe third coat in the bilge area. Looks much better now. Time to start putting everything back together.

 

[Trooper82]

Re: 1985 Conroy X-19 I/O Transom Restoration

That looks awesome!

 

[nrasnake]

Re: 1985 Conroy X-19 I/O Transom Restoration

Thanks Trooper. It feels so good to be done with all of that.

 

[GT1000000]

Re: 1985 Conroy X-19 I/O Transom Restoration

Looks Superb! snake...
Great job!:thumb: