Stringer repair

[Scott Danforth]

cool, not sure I would want to ski at 70mph......35 is fast enough to fall...

 

[Baylinerchuck]

Wow, I’m with Dan.....a Potomac River enema at 30 mph is uncomfortable enough, let alone 70 mph. Better be wearing a stainless steel chainmail pair of under drawers. :eek-new:

 

[bjf66]

looks like I was correct boat was copied from levi design which accounts for fine nose profile
managed to get another picture of the old girl back in the day

 

[bjf66]

nice weekend in melbourne, 20-25C hello spring
got all the important jobs out of the way for the boss, fertilising,pruning trees etc,
That left the rest of weekend to sort out the K-planes

made another template for the required pattern, started on starboard side first
had the threaded holes in plate welded up, as wont be using these

cleaned up the plates with paint stripper, took a few goes to get it all off and to remove the paint from trim pumps

Then marked the transom plates with template and used trusty 4" cut off grinder to cut and dress smooth radius on the cut down transom plates
drilled the plates and straight through transom

due to transom being contoured will have to add some filler, behind plates to get them flat. will make up dummy plate, and follow the profile of the transom plates and pull up on the bolts holes to get the surface flat.

2 bolts inside transom are below floor so will address that issues once I get motor out and start to do the finish prep work

need now to turn attention to fabricating actuator brackets in 6-8mm stainless

 

[bjf66]

Mercruiser actuator substitution
Had some difficulty tracking down the Mercruiser rubber bushes for the actuator rod mounts on the K-plate as appears my cylinders are the older model #78439

Then started to look at alternatives
managed to find some Nolathane #47009 for leaf springs for Nissan 1980-86, 4 in packet for A$45

https://www.nolathane.com.au/product_detail.php?part_number=47009,
Cut 65mm length of stainless tube 16mm OD/12mm OD which worked out well

need to find the colour code reference for mercury black colour

 

[bjf66]

both trim tabs lined up reasonable straight and in same location
making packer up behind transom mounting plates
using 4* 1/2" x 2" UNC stainless bolts through hull
need to review how the hydraulic lines will go

 

[Baylinerchuck]

Really enjoying watching a build of this style. Thanks for posting updates.

 

[Scott Danforth]

with the boat on plane will the K-planes even be near the water being that high up the transom? based on the pic of the boat with the OB mounted, not sure.

 

[bjf66]

Ordered Metre of 8mm 316 stainless flat 100mm wide
for the trim hydraulic connector through transom useD outboard transom bolts nice and long
maybe able drill out 2 of the bolts for the Arneson hydraulic steering
tacked up the brackets for actuator Will get them rig welded next week

will drill out the transom holes larger and fill with resin /PB and then drill out for the 1/2” bolt hole

 

[bjf66]

Trim cylinder brackets
brackets welded up, much neater job welding with the tig, as opposed to the functionality of the Arc welder..
brackets look prettier hanging off the transom

Used Quicksilver outboard bolts with hydraulic fittings, same internal diameter as K-planes fitting as well as bolting plate to transom
not sure which one was used as 2 different bore sizes 3/16" /AN3 and 1/4"/AN4
22-67667 - port
22-67666 - starboard

need to purchase another one 3/16" connector to have all the hydraulic transom bolts the same 3/16" bore
or I suppose use 3/16" to 1/4" adapter

outside of trim pumps now sorted

 

[bjf66]

Arneson trim cylinder /transom hydraulic fittings:

On with hydraulic fitting
the cylinder uses 7/16"-27 tpi threads, so can use AN4 hoses
had a look at mercury K-plane trim hydraulic fittings which are the same so decided to utilise this and cut and lengthen the fitting with 16/12 (SCH80 ) stainless tube, length approx. 30mm to allow plenty of adjustment on inside of transom for locking nuts
will organise the stainless AN4 fittings for cylinder, 1*45 degree and 1*straight

 

[bjf66]

when and purchased the 316 #16 gauge stainless tube -1m length, and 2* 90 degree bends, to fabricate the turbo waste gate exhaust

 

[bjf66]

transom backing plate for trim tab/K-plane transom plate

• made up backing plate using 6mm gurit cored board, laminated 2 layers of each 300grm CSM & 612grm Multi-leave cloth, let this harden
• sanded transom to remove gelcoat back to glass
• clean up acetone
• primed both surfaces first with VE mix 2% hardener
• make up PB with 6mm CSM/West 403 filler
• glued
• hour latter rough sanded
• will finish when I sand the transom for final prep

 

[bjf66]

• trim tabs mounting all finished, rough sanded, needs to be filled and blended when I finish sanding the transom
• purchased the AN3 3/16-24 stainless fitting in between the hydraulic transom pipes and AN4 1/4" hydraulic lines for Arneson trim cylinder
• need to sort out the Arneson steering cylinder hydraulic lines from transom to cylinder, will most probably make the transom fitting as they need to be 5" long x AN6 3/8" x 1/4NPT connections
• mocked up one of the turbo wastegates exhaust, and got half the pipe tacked up. Using 316 S/S #16 gauge, 45mm pipes
• hopefully be able to put some time aside this week and tack up the other pipes and get them tig welded at end of week
• after the wastegates are fabricated can start to pull eveything apart and get on with final sand down

 

[bjf66]

Arneson trim cylinder /transom hydraulic fittings:

On with hydraulic fitting
the cylinder uses 7/16"-27 tpi threads, so can use AN4 hoses
had a look at mercury K-plane trim hydraulic fittings which are the same so decided to utilise this and cut and lengthen the fitting with 16/12 (SCH80 ) stainless tube, length approx. 30mm to allow plenty of adjustment on inside of transom for locking nuts
will organise the stainless AN4 fittings for cylinder, 1*45 degree and 1*straight

Arneson trim cylinder /transom hydraulic fittings:

On with hydraulic fitting
the cylinder uses 7/16"-27 tpi threads, so can use AN4 hoses
had a look at mercury K-plane trim hydraulic fittings which are the same so decided to utilise this and cut and lengthen the fitting with 16/12 (SCH80 ) stainless tube, length approx. 30mm to allow plenty of adjustment on inside of transom for locking nuts
will organise the stainless AN4 fittings for cylinder, 1*45 degree and 1*straight

 

[bjf66]

Arneson steering:

• figured out what was need to make the fittings in stainless
  • order 4* AN6 weld on fittings
  • managed to get 12mm ID/1/2" x 150mm long BSP threaded pipe
  • 4* stainless end caps for pipe,
  • 4* locking nuts for the BSP threaded pipe
  • tig weld fittings up, should be all good

Turbo waste gates

• using 45mm 316 #16 S/S tube
  • 4* 90 degree bends
  • 1m length of 45mm tube
  • tacked wastegate V-band on to tube
  • cut tube length approx,. 150mm long tacked on to turbo collector
  • drilled out the hole in collector and use carbide burr to clean wall up and make right transition
  • get the tig welded tomorrow

 

[bjf66]

Arneson steering hydraulic bulkhead / transom fittings came out good

 

[Scott Danforth]

you are currently in the tedious small project phase.....to those of us that have been there, great job...... to those that dont understand the level of resto-modifications, the OP is building stuff you cant buy......

 

[bjf66]

Scott...yes you're correct, the time consuming stuff is all the little jobs that need to be done, and that are not off the shelf to purchase like a normal factory build.
However one day at a time, pushing forward to knock those jobs over.
Need to be thinking ahead 4-5 steps ahead, to make sure the little jobs preparation is all stacked up waiting inline

the new website is a fresh of air

 

[bjf66]

Turbo waste gate fabricating
after a little horsing around with pipes and angles, managed to get the part of the waste gate pipe sorted from collector to waste gate.
Now to position the pipes again and measure and cut the pipe from WG out of engine hatch through the rear deck
Plan is try and finish this during by end of this week
Need to work on the angles, cutting and tack welding as I go
The pipe will be able to move as will have 1/2" gap around 1.75" pipe as it goes through deck, and then will use silicon to seal between pipe and deck, similar to transom exhaust pipe setup.
Lets see how it works out