'1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

[lowkee]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Thats really good progress. Nice quality work.

nice work... I'd like to do that some day...

Wow! What a nice job ... Thanks for sharing.

Lowkee, you rock man!

Wow guys, thanks for the compliments! I must say, I began this thread as a means of creating an all-in-one thread, as most restore threads I read before beginning my restore either had tons of photos or tons of information and tips, rarely both. Nowadays, I'm just hooked on updating it and passing on the experience as well as the knowledge. It is truly exciting lately as things begin to go back into the boat. The tear down just sucked, and I make no airs about it. For anyone just beginning your restore or contemplating it, just get through the tear down as the fun begins after that. From there, it is all creative juices and instant gratification. Every day I work on the boat I can turn around on my way out of the garage and see what I accomplished, and it really feels good.

Now, on to the real stuff.. photos!

Not trusting my deck cutting skills, I decided to make some solid platforms for the edges of the deck to rest on. They are made from 2x4 bits cut at various angles (from 16-45 degrees) then poly'd and glassed to the hull. I wasn't too worried about making them perfectly waterproof, as they aren't crucial, just there to make me feel better and to add support until the deck is fully glassed in.

The dog bone is now mounted. I measured the ski locker length before placing it in, as I would hate to find it is in the way when cutting the locker hole. Once the PL sets I will tab it with glass just as I did with the bulkheads. Also notice how the deck supports go right into the bow. I was most concerned about that area, as the chines, combined with sharper angles, make for difficult deck cuts and I wanted to ensure proper support in an otherwise unsupported area.

I installed the stringer lifts. They are 1/2" plywood cut in ~1" strips and PL'd into place. Notice the fuel tank is nicely under the stringer tops, now. I have lifts drying on the poly table for the bulkheads, dog bone and fuel tank which will go in tomorrow.

Tomorrow I begin marking and cutting the deck! Milestone, baby!

 

[lowkee]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Hell Freakin' Yeah!

The deck is ready!!!!

From this:

To this:

After marking, snipping and doing it all over again with the pink foam sheets, I finally bit the bullet and cut the deck boards.

The edges are cut at a 45deg angle in order to make it slightly more flush for glassing and hopefully require less filler.

The bilge area was less work than I imagined thanks to the pink foam sheets. I simply cut a bit, testing it, then trimmed some more until it fit perfectly.

Tomorrow comes glassing the bottoms of the deck boards, then I'll be slicing up the foam I used for the templates and throwing it under the deck. Last I'll be glassing the deck boards to the hull!! Woohoo!

I'll take some snapshots of how I marked up the pink foam for final cutting, as it took some time to get a working groove going and if I can save someone else the pain, all the better.

 

[chrishayes]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Hell Freakin' Yeah!

The deck is ready!!!!

From this:

To this:

After marking, snipping and doing it all over again with the pink foam sheets, I finally bit the bullet and cut the deck boards.

The edges are cut at a 45deg angle in order to make it slightly more flush for glassing and hopefully require less filler.

The bilge area was less work than I imagined thanks to the pink foam sheets. I simply cut a bit, testing it, then trimmed some more until it fit perfectly.

Tomorrow comes glassing the bottoms of the deck boards, then I'll be slicing up the foam I used for the templates and throwing it under the deck. Last I'll be glassing the deck boards to the hull!! Woohoo!

I'll take some snapshots of how I marked up the pink foam for final cutting, as it took some time to get a working groove going and if I can save someone else the pain, all the better.

Dang it, I gotta get moving...you are passing me in a quick minute! You have now inspired me to go and cut a template for my deck. Thanks...for making me work on a thursday night! Loooks awesome man, must feel pretty good! I am amazed that there is absolutely NO keel support in your boat. Mine is VERY heavy glass but still had a full length stringer all the way down the keel to the bilge. Hmmm, guess I dont feel so scared about modifying mine now! Keep going, just slow down a bit and let me catch back up. Please?

 

[Mr.Swee]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Two Questions!!

First of all, everything looks great.

1. Outdrive: Can two people move this or do I need a cherry picker?

2. I noticed that you cancelled the foam part of your restoration. Why?

I'm about ready to tear into the transum area. I need to remove the outdrive and the motor. I just ordered the manuals for my 1987 OMC 3.0 today. Your several steps ahead of me, what the best way to remove the outdrive?


Thanks

Eric in SC

 

[lowkee]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Two Questions!!

First of all, everything looks great.

1. Outdrive: Can two people move this or do I need a cherry picker?

2. I noticed that you cancelled the foam part of your restoration. Why?

Eric in SC

Hi Eric,

I was able to remove the outdrive by myself, and I'm no big guy (6'1", 160lbs). I think bean pole with a mild gut is more accurate for me . If I were to guess the weight, it felt about 70lbs but was awkward to lift, since you are crouched and leaning, but it came off without trouble.

As for the foam, I figure if my boat sinks i want it to stay sunk. No way am I doing this restore twice. If I swamp my boat, I'll be shopping for a new one. If I don't sink it, I want it to last for a very long time and foam, known to hold water, isn't conducive to that end. Having said all of that, I do plan to put the pink sheet foam I made the deck templates with under the deck. Some foam is better than none, and as long as I keep the foam in the upper areas it should stay dry. I also hear the sheet foam is much better at keeping dry, unlike the pour in junk.

 

[BLC]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Wow!! nice work, very impressive. How long did you have this boat for before you decided to do the restorstion. Isn't it a shame that some one would let a boat or other recreational product get to be in this shape. there are lots of smowmobiles in the area that I live in and I see so many of them just sitting out in the elements all year long. You would think that it would make sence to spend $10 at wall mart and buy a tarp to cover it up and protect your $10,000 investment

Once again excellent work, can't wait to see the finished product

 

[ou18]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Nice work LowKee. I like the way your doing it. You've definitely made my job easier by posting as much as you did. I appreciate it. Im hoping to get back at mine this weekend after two weeks off from doing any kind of work on it.
Keep it up, looking forward to seeing pics of it floating in the water.

 

[chrishayes]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Hey man, do you care to explain how you did your deck template? I thought it would be fairly easy It wasnt...I tried using cardboard and marked it at center all the way from top to bottom then took measurements across the boat at 6" intervals and transfered those to the cardboard. It kinda worked but the curve of the bow was hard to duplicate freehand so my template ended up looking like a big arrowhead or triangle where the shape of the boat is more rounded. Help a brotha out man! please:redface:

 

[CheapboatKev]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Lowkee..
Had to pop in and say..
U R ONE CRAZY SUMBEACH!
Man thats great work, I would have walked away from a project that huge..good job man!

I feel ya on the template..I tried everything possible..Whatever I used, cardboard..large rolls of construction paper..Any template I had, wasnt what I cut on the plywood..My jigsaw had a mind of it's own I guess!
I freekin wasted 3 or 4 sheets...

Again..good job

 

[bear_69cuda]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Looking great boss!

You dominate brutha!

 

[lowkee]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Wow!! nice work, very impressive. How long did you have this boat for before you decided to do the restoration?

Thanks BLC. I owned it about 3 weeks intending to do a carpet replacement and some new vinyl :redface:. In my 1st post you'll notice a 10 step of restoration denial.. Those are the exact 10 steps I went through. I've managed to repeat step 10 on a regular basis

Nice work LowKee. You've definitely made my job easier by posting as much as you did. I appreciate it.

Thanks ou18. I'm glad my posts are of help to others for their boats. If something sounds convoluted or if my posts skip too many steps, let me know and I'll try to restate it better or with more detail. I'm trying to save the next guy the time it has taken me to figure some of this stuff out, just as others have helped me a ton.

Hey man, do you care to explain how you did your deck template? I thought it would be fairly easy It wasnt...

Hehe. Yeah, I got some great 4x6 sheets of cardboard thinking "YAY!".. yeah right! It flopped all over the place and I didn't dare cut the ply with it. I ended up using 4x8 sheets of pink foam ($9/ea at HD or Lowes.. I used four) and they worked much better. Using the pink foam you can cut it much easier with a razor and get clean curves, unlike cardboard. I made a video how-to using the pink sheets, I just haven't edited it for YouTube, yet. I'll try and get on that tomorrow.

Lowkee..
Had to pop in and say..
U R ONE CRAZY SUMBEACH!
Man thats great work, I would have walked away from a project that huge..good job man!

Again..good job

Thanks Kev. Yes, I must be crazy, because I now just go outside and work on the boat.. automatically. My brain doesn't even say "I wish I was doing xxx today" anymore, which is probably means I've gone off the deep end.. without a boat. I love the lines of the boat, so I'll keep at it until she's finished. Heck, I have all the parts to finish it, so I won't be saving any money ditching it now :redface:. Those $2900 beauties I see on CL sure look nice, though. I've considered buying a 'until it's finished' boat, but in reality, I'd never finish it if I bought another boat. I know myself too well. .. that and the new boat would likely need a full restore, too! Then i would have to kill myself

 

[ou18]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Just one question Lowkee. How did you pull the cap and stop the hull from spreading out. What did you do to fix that problem. Im at a point where, I either need to pull the cap, or work around it. My Bow, the cap, dash, bow seating is all one unit. So it will be a bit heavy getting it out, but i also dont want to have the hull spread apart when I do it.
Any suggestions.

Still need to pull the engine, once i get that done, Im full steam ahead.

 

[lowkee]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

How did you pull the cap and stop the hull from spreading out.

When you pull the cap while the boat is on the trailer the hull spreads a little bit, but not much, so you can cut everything to size. Just make sure when you glass the deck back in you have the cap back on so everything is exactly where it needs to be. The cap doesn't need to be on there for good, just resting so the hull is shaped correctly.

 

[ou18]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Gotcha. I think as precaution i may add some lumber to the side rails of the trailer to fill the gap between the boat and the trailer rail. And maybe some going up vertical as well. This was it doesnt spread at all and I dont have to worry about the cap going back on.

I think im going to have build a double gantry to get this thing off the boat. Being the bow area is one big mold. One to lift the bow, one to lift the stern, and maybe a cross member between the two to life the center and support it until i can pull it out and set it down on the ground. Sounds like i have some gantry building to do. Yay me..

Thanks for the insight

 

[lowkee]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Well my friends, it has been slow going since my last update, but there is progress to report. I mainly had some unrelated fixes to do (had to fix my router lift and make saw horses) as well as some pre-deck-0install items to check off before I move forward on the deck install itself. Let's recap, shall we..

In order to be REALLY paranoid, I made up some cross members for the decking. These will go across the fuel tank as well as at the seam of each deck board. This way the seams will be guaranteed to line up perfectly.

Since I second guessed myself and lowered my stringers 1/4", then realized the fuel tank sat above them, I had to raise them that same 1/4" again. Some thin 1/4" plywood strips did the job nicely. Notice the notches cut out for the cross members. Those will be installed next.

Here is my new and improved router lift. It contains about $30 worth of hardware and works as well as the $300 ones you buy retail. It is raised/lowered using a 9/16" socket. I use my cordless drill to adjust it. It can raise the router high enough to allow bit changes above the table and lower it enough to allow me to use the table for other things.
The router can be easily removed by loosening that 1/2" nut, which tightens/loosens a simple wooden clamp (a 1/4" slit sawed 80% through a piece of 3/4" birch plywood).

Early on, during the teardown, I noticed the keel was pretty worn, so I poly'd on 3 layers to reinforce it. Once the deck goes on this area will be inaccessible, so it was now or never.

 

[lowkee]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

I'll have to replace the horribly corroded nuts for the bow and stern eyes before I flip the hull. I certainly don't want all of my hard work crashing to the floor because of one bad nut (and no, I don't mean me)

More bad nuts. These are barely still existing as nuts.

Here is the new ski locker cover. The board is slightly too thin for the frame, so I'll have to make a spacer for it, maybe out of luan or just a bead of PL, as it is only 1/8" off. This was a pain fitting, as you could only shave off tiny amounts at a time and, of course, the frame wasn't perfectly symmetrical.

Here is the bow deck board. Note the chopped off tip. This is to allow the anchor line, chain and excess water to drop into the ski locker area. I have a really long anchor, so hopefully this will allow me to fit it into the anchor spot under the center bow seat.

That there is a lot of fiberglass mat.. which will soak up a lot more resin. Likely two gallons per side of the entire deck, maybe three. I plan to use a foam roller for these, as a brush will just take forever. The nervousness of installing the deck is building..

 

[JoeyInKC]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Man, its looking great!

Funny thing is, I was one of those guys that said once my boat is done, we will be at the lake every chance we get... lol... since the 4th, we have been busy every weekend... ironic, dont you think?

Keep up the good work... I plan to have more posts this winter when I pull the motor back out and do an overhaul... want to gut her, bore her and slap her back in. I'm thinking about getting a paint job this winter as well... but anyways....

stay strong!

 

[WAVENBYE2]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

WOW AWSOME!! I have learned so much about my own boat by reading, the pics, and your videos!! You answered alot of questions that I had with out me having to ask. I am definitly watching everything you did and are doing, this is a great learning experience for me, kind of like sitting in a class room, Thank you for all the time you put in to show us your complete restore step by step progress from start to finish. I can definitly ask you for your opininion when I start doing the work needed on my own boat, But I am watching and learning too,can't wait to see the captian chairs, was thinking of going that route too, now I can see how its done. Keep up the great work, I am definitly following your thread and progress, Thanks again...........................Pat

 

[lowkee]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Man, its looking great!

Funny thing is, I was one of those guys that said once my boat is done, we will be at the lake every chance we get... lol... since the 4th, we have been busy every weekend... ironic, dont you think?

Thanks Joey. I plan to get all the boating in a can once this is on the water.. I even plan to move closer to it as encouragement!

WOW AWESOME!! I have learned so much about my own boat by reading, the pics, and your videos!!

Thanks Pat. Welcome to the thread! I have some more videos coming, but I've been fighting between getting things done and getting video ready, and I'm just barely behind my latest iteration of my 'Yeah, right!' schedule. I'll try to post em soon, as i think they will be helpful to quite a few in this section.

Now, on to the update!

Well, I was hoping to have the deck installed last friday, but I began to get paranoid and started adding bracing and supports everywhere. This project is just not something I want to do again, so I am going crazy with last minute additions. All in all, i am not far off, as I should have the deck installed tomorrow evening, which is pretty killer. I'm all excited to get started on the hull painting, now.

Well, I wasn't far off on my estimates of resin usage. The deck (top and bottom) soaked up a full 5 gallons of resin. There is a full layer of mat on each side and they shouldn't be budging any time soon! I have no idea what I'm going to need six sawhorses for after this project.

Notice the big strip of glass on the ground.. well, I was hoping to tab the deck boards into the boat using the bottom layer as well as the top, but during the wetting I couldn't figure any means to keep the tabs from getting wet and hardening, so I had to grind them all off.. what a chore!

After the top was complete, there was more grinding to do. Every piece had at least some overhang to remove. Here you can see the ski locker hole. I moved it up towards the bow in order to keep it all within a single piece of plywood.

 

[lowkee]

Re: '1990 Bayliner Capri 2050 BR - Deck, stringers, transom, custom interior'

Here is how I applied the resin on the deck wood. It worked beautifully! I highly recommend getting this exact setup for your project. The roller is a mini-sponge roller and a normal flexible plastic paint tray. Each time I use the tray I let it sit until the resin is hard, then I simply flex it and it pops right out; Couldn't be easier!
The roller sponges do de-glue from their roller structure, but it isn't difficult to keep it from falling off the roller handle, just don't go swinging it around.

Here is the ski locker cover ready for glassing. I haven't tested it yet, but I'm hoping the 1/8" the plywood way lacking to fill the locker cover frame will be spanned by the two layers of glass. If not, it should be REALLY close and I'll be able to simply bridge the gap with a tiny bit of filler prior to painting it.

All pieces are glassed, ground smooth and waiting to be installed.

The cross members which will support the seams of each deck board are glassed, bedded and glassed again. I also took the opportunity to rough and scuff the entire length of the hull where the deck tabbing will happen. I will also run a thin length of glass along the chine where the deck will rest, as it looks a little decrepit. Better safe than sinking.

To follow my deck-must-withstand-the-jolly-green-giant paranoia, I added a bit of bracing to the inside lip of the ski locker hole. I considered adding an entire ring around it, but settled for a couple of boards with major glass reinforcement.