Bighoss' 16ft SS Rebuild

[Bighoss]

While reading the restore threads for the past year I've wondered if I could pull this off with some dignity intact. Carefully considering my ability and armed with the information all of you provided, I'm going to give this boat the restoration it deserves. I'm following the community protocol and posting as many pictures as possible. Please don't hesitate to speak up and give any advice/critique that comes to mind. I've done a few boats, but only duck boats that required the ability to stay afloat. This boat was found reading the CL thread daily. Thanks to CBGALE I saw a project boat with a 2001 Trailmaster trailer and a 50hp Mercury for $550. The interior was completely shot and the motor rough, the hull however was solid with a trailer in like new condition. After 2 weeks of working between work and the continual rain in Northwest Ohio here's the progress.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

With the boat gutted I start removing paint. This time I'm stripping the boat to bare aluminum. I know some advise against it but this boat has roughly 5 coats of paint and none really bonded well. I find at least 3 different colors and most of it was latex house paint or some poor quality paint. I started using an electric paint remover but if you own one you already know this was a poor investment. I'm forced to use a metal scraping tool, wire brushes, drywall sanding sponges to wet sand and steel wool batting, a lot of work but the new like aluminum appearance speaks for it self. I've read that paint stripper can do more damage to the aluminum. Has anyone heard the same? I have the entire hull left to do, if there's no risk involved that will be the choice method. The tack cloth and primer I plan on using listed below.


http://www.highseasmarine.com/Moeller-025800-Zinc-Cold-Galvanizing-Iron-Primer-p/114-025800.htm
http://www.amazon.com/dp/B00164CDZE/ref=nosim?tag=finishingcominc

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

Once everything was removed I had to vacuum all the Styrofoam leftover particles. Using an air compressor with pistol attachment I blew all the mud, wood pieces and foam from the gunnels at least three times before pulling out the power washer. After power washing it still doesn't satisfy me, I wet sand with 120 grit, wire brush where Gluvit needs applied and steel wool the entire bottom. One more power washing and I'm feeling like I'm ready to apply Gluvit. The problem I have with the notorious glue on the side walls makes me run to the computer again. The search for info. only makes me think I'm not alone. Any ideas to get this stuff off? Anyone know what the $^&! it is? I'm going to use it again somewhere because it sure bonds to aluminum.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

Almost every rivet was either broken or too loose to rely upon. I drill out and replace them with all aluminum 3/16 rivets. The side wall supports get the same. West Marine scalps me for .20 cents for each and the bill for these and the Gluvit is embarrassing. The Gluvit costs $79.99 for 2lb! With enough rivets to get the job done I swear under my breath thinking of all the sites you guys have posted listing this stuff for half the price. Time being an issue I race home to get started. I have no splash down date in mind but my patience level when I start a project forces poor decisions. Not a virtue I'm proud of but I work for the government and most of you know.... money is no object to us. In fact, there is no budget for this restore either. The wife being a banker I just keep going to her until I'm in way over my head. All receipts promptly shredded after purchase.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

The floor nearly completely rotted needed removal as well as a transom that crumbles in my hands. First thought that the removal of the transom would be easy, I had no idea the bottom half would hang on like a bear trap. After removing every screw, bolt and washout drains I borrowed an idea from Jasoutsides's restore thread by using a come along over the neighbors tree. After lifting the boat trailer and all off the ground My 6'2 275lbs standing in the boat was enough to pull the last part out. Whoever said the years of hops and barley enriched beverages combined with a steady diet of pizza would never pay off has never tried to pull a water logged transom from an aluminum hull.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

Wood out, I discover some areas of pitting on the aluminum. None all the way through but getting close on a couple. This is where team Starmada comes in! Any ideas, proven or otherwise? I've done some research and found a product called Metal to Metal by Evercoat. Has anyone used it? Should I insert a 3/16 aluminum and laminate it?


http://www.handsontools.com/Evercoat-889-Metal-2-Metal-Aluminum-Filled-Filler-quart_p_10755.html

 

[Pugetsound]

Re: Bighoss' 16ft SS Rebuild

Can not enlarge your photos?????? You sure do nice work.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

I cleaned the inside of the transom well by wet sanding and steel wool. I'm ready to make a template, being the old wood was no example due to severe rot I used a large piece of cardboard. By tracing the outside dimension of the transom I'm able to get a rough form and cut down to fit inside the transom well. After making sure this is a perfect fit I rush to Toledo Plywood and pick up a sheet of 3/4 marine grade ply. For $85 I'm certain there's no voids in the sheet...more on that sarcastic remark to follow.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

I just noticed the smaller pics. Yup, I'm working on it right now. Thanks for the heads up, I thought they'd enlarge. And seriously thanks for the encouragement.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

With my trusty cardboard template, my Father-in-law and my $85 piece of 3/4 marine grade I start cutting this jewel made of wood. Remember that sarcastic remark? While cutting I find several voids in this ply and start wondering if the cardboard will hold my 90hp! The rain starts again just in time to cool me off and save the life of someone at Toledo Plywood. Finally we finish and manage two pieces with a couple small voids thanks to my Father-in-laws life long engineering profession.

 

[veilside180sx]

Re: Bighoss' 16ft SS Rebuild

Works better if you host them on photobucket, flickr, etc and then just link them here with image tags.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

Got it. I just finished creating a Photobucket acct. Kind of a before and after theme. Thanks

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

Boat before gutted and stripped down and after.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

Gutted before scrub down and power wash.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

Washout and transom before and after.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

Hull scrubbed, air pistol used with compressor to clean our ribs and other tools used.

 

[veilside180sx]

Re: Bighoss' 16ft SS Rebuild

You took clean to a whole new level...and I thought we did a decent job on ours.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

Carboard template, plywood cut for transom with a couple voids.

 

[Bighoss]

Re: Bighoss' 16ft SS Rebuild

Thanks, it was a ton of work but worth it. I would never have gotten away with just roughing the paint on this one... it was a total loss. If there's a weight loss program more effective than this project I'm not trying it. Bighoss' weight loss program - dvd's for sale on I-Boats.

 

[jasoutside]

Re: Bighoss' 16ft SS Rebuild

Man did you ever get that hull clean! Nice work