1991 15 foot Bayliner Trophy 1500 Sport (whaler type) Transom Repair

[msweetman1]

I could not have done this project without the help and advice from Woodonglass.

My boat started to peel away from the knee braces and I took the transom bolt plate off to investigate. Needless to say, I discovered that the previous owner had did a really poor job in trying to repair the damage beforehand (he used silicon sealant to patch up some holes after cutting away the skin).

So therefore, after discovering this issue, my heart sank because I had no idea on how to handle this repair. I eventually took the boat to a couple of repair shops in trying to get estimates on the repair. I was given quotes from $1,500 to $3,000. At this point I was distraught in knowing I didn't have this type of money and felt the repair was more than the worth of this boat. So after thinking about it for a couple of days, I figured I would try to repair the transom myself. I had the thinking of if I do anything wrong in the repair, that I would right it off as a loss and try to find another boat to replace. This is the boat that needed the repair.

 

[msweetman1]

Here is what the transom looked like before the repairs took place. I had the non skid rubberized material on the gelcoat that was put on from the previous owner. I bought this boat 4 years ago and am surprised the transom held up this long.

 

[msweetman1]

So I started to come up with a plan. My first thought was what about the Seacast system. $500 for the kit sounded really reasonable to me. After researching how to do it, I was scared off by the fact I would be using a chainsaw to cut out the old transom. Knowing my luck I would cut right through the back end of the boat. So I decided against it. Then I came across this site and started to read posts after posts on how to repair the transom. After reading a few I came across Nurseman's post and was feeling confident I could do this. I saw Woodonglass's guide on stringers, transom, and deck repairs started to understand what is needed to get this job done. So I started the process. I figured I would spread the project out doing something each weekend. The first weekend I did the demo and grinding way the old fiberglass.

 

[msweetman1]

After sharing this with Mr. Woodonglass, He stated that I did not go wide enough on the cleaning off the old gelcoat and fiberglass. He has been a big help on this project with telling me how to do the PB resin, the supplies and amount of resin needed, and the answers to the what ifs I had. So while I was demoing the boat and prepping it, I ordered my supplies from US Composites. While I was waiting for my order I proceeded on cutting the new transom and gluing the two sheets together. With Woodonglass' suggestion, I went with 1 full sheet of AC grade exterior Douglas Fir 3/4" plywood. Here is the new transom at the beginning stage.
Notice I made a couple of oops and was assured from Woodonglass that this was not a big deal since the PB resin would fix it.

 

[msweetman1]

After I let the transom cure for a week, I received my order and started to prepare the PB resin to attach it to the boat. I had the transom attached and glassed in the same weekend and waited to do the stringers for the following weekend. Here is some of the photos.

 

[msweetman1]

If I ever do this process again, I would do something different. I drilled my core holes for the transom bolts and transom hooks before attaching to the back end of the boat and filling it in with the PB Resin with the ooze holes I had made. I would not do this next time, if there is ever one. I would wait on this process because while re-drilling the holes for the bolts and hooks, going through the cured fiberglass cloth, I have left some areas on the edge of the drill that need to be touched up with resin.

Well, I have let the transom cure for a week and put the stringers and knee braces on. I will now go test the boat for any structural weaknesses and leaks before installing my flooring. I had made some temp flooring for right now to hold the battery and fuel tank. Plan is if everything works out like they should I will install floor and fill in the void under the floor with the closed cell expanding foam. I also ran out of cabosil on the last application for the knee braces, so I used epoxy putty, which is the whitish gray seam on the knee braces. I plan on reinforcing the seam with the PB resin once I get more cabosil and tabbing them on the transom.


Thanks again Woodonglass for all your help to this DIY rookie.

 

[kcassells]

Nice work MS!

 

[Corjen1]

Looks Great!!

 

[msweetman1]

Thanks for the compliment.

 

[Woodonglass]

MSM, YOU did the work, I just Blabbed a lot!!! You're gunna have a boat that you can be proud of, and that your family will be safe in when you're on the water. Take PRIDE in your efforts.

 

[msweetman1]

Thanks WOG. Maybe past it down to the little one in 8 to 10 years.

 

[kcassells]

MSM,
Are you just pulling our legs? You sure you haven't done this before! YOu are right on the Money!

 

[msweetman1]

Thanks KCassells. I have not attempted a repair as large as this one. I did some ding repairs to the boat and my surfboards but nothing this large.

Thanks for the kind words.