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98Roo
06-09-2012, 12:34 PM
I picked up this '98 Outback from close to Jacksonville, FL almost two months ago. It was obvious it was never taken care of, never covered, and never waxed, but it only had 320 hrs on the clock. I knew it needed a little work, all new interior, and some gel coat work but didn't know it would need a Transom repair. There were gel coat cracks all around the swim platform mounting brackets and I could actually pick up on the platform and watch the transom flex around the brackets. I could also see it had been messed with before because there was blue rtv around the bolts and brackets.

Luckily I only paid enough for it that after the repairs I would still be right at the NADA price for a boat in "good condition." Plus I figured that for what I paid, I could at least part it out for that much.

Here's what it looked like when I bought it.

http://i64.photobucket.com/albums/h192/redej8/98-moomba-outback-ski-boat_1g5vg.jpg
http://i64.photobucket.com/albums/h192/redej8/photo1.jpg
http://i64.photobucket.com/albums/h192/redej8/photo.jpg
http://i64.photobucket.com/albums/h192/redej8/photo2.jpg

98Roo
06-09-2012, 12:36 PM
After I got it home I started tearing into it. Ripped all the interior and carpet out and removed the windshield to get repainted. I also started digging into the transom to see what repairs it would need.

http://i64.photobucket.com/albums/h192/redej8/IMG_2970.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_2969.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_2977.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_2966.jpg

98Roo
06-09-2012, 12:39 PM
Also started cleaning up some things like the gas tank which was filthy. You can see the access holes the previous owner cut into the floor to access the swim platform pieces. He put in two small pieces of steel plate and washers on the bottom two holes of the brackets. He cut out the mounting "pad" with a hole saw to put the washers in with thru bolts. This is why the transom gel coat cracked so bad because it was just a thin layer of fiberglass and gelcoat supporting the swim platform.
http://i64.photobucket.com/albums/h192/redej8/IMG_2967.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_2967.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_2964.jpg

More to come.

98Roo
06-09-2012, 01:51 PM
Here's a few shots of the transom after everything was removed. I also cut the floor back a bit to get a look at what I was dealing with. I forgot to get before pictures of the "pads" that the lag bolts screw into before I cut them out. They were just square piece of plastic sandwiched between fiberglass and glassed to the transom.

http://i64.photobucket.com/albums/h192/redej8/IMG_2976.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_2979.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_2981.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_2984.jpg

maxpower220
06-09-2012, 02:40 PM
Sweet post. Nice pics of the progress. That motor looks really good, especially compared to the rest of the boat.

98Roo
06-10-2012, 02:55 AM
Here's a few pics of the windshield. I decided to get all the parts powercoated flat black instead of painting it since it should be a little more durable.
Before
http://i64.photobucket.com/albums/h192/redej8/IMG_3016.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3020.jpg
After
http://i64.photobucket.com/albums/h192/redej8/IMG_3096.jpg

Also a shot of about a 1/6 of the boat wet sanded and buffed (no polish yet) before it went to the fiberglass man.
I'll say it should turn out pretty well once I have a chance to finish it.
http://i64.photobucket.com/albums/h192/redej8/Polish.jpg

NCSUmoomba
06-10-2012, 02:15 PM
That is awesome. Props to you for stepping up and saving this boat. Most of the time, boats in this shape end sitting in someones back yard for eternity. It's great to see folks not afraid to tear into projects themselves. In a two or three years, once I get a V-drive, I am going to do something similar to my Outback, as it needs new carpet and vinyl. My wife also wants a dedicated ski boat, so the tower and all that stuff will be removed. My windshield needs a repaint to, maybe I will go the powdercoat route.

One thing I have noticed about our boats when looking about replacing the carpet,you can probably see how it is underneath the seat bases and hull top. To do a carpet replacement of factory quality, I am planning on splitting the hull at the rubrail. With your boat at this level of deconstruction, you might think about doing the same. All that is required it to pop off the rubrail insert, and then remove a bunch of screws, and the top can be lifted off the bottom. It m,ight be pretty flexy and it might require a few extra hands to lift it off, but i seems that it might make the carpet install much easier.

Good luck, and keep the posts and photos coming. Very cool!

98Roo
06-10-2012, 03:43 PM
Thanks! I have a lot more pics to post I'm just slow at doing it. I found a soft spot in the floor so the whole floor got replaced which means the top came off. Stayed tuned.

zabooda
06-10-2012, 07:55 PM
98Roo, your pictures are worth a million bucks to me. I've been fortunate to have a well maintained boat but if I need to dig in sometime I have pictures to look at. A few thinhs to think about is the window frame for that year would spread apart at the walk-thru so reinforcing the frame on the drivers side with another small screw keeps the top frame from pivoting. Another area I need to fix someday is the edge around the sear where the observer sits. It appears that people (including me) would stand on the cushion and the Fiberglas was strong enough so there is a crack. I put a board underneath to keep it from flexing but glassing in some reinforcement would fix the problem. I have 500 hours on mine and other than some seat cover replacements that is about all I did.

Great job and thanks for my library pictures. Hopefully, I won't need them.

98Roo
06-10-2012, 08:10 PM
Glad I could provide you with some pics! I might consider reinforcing the windshield with more screws. It appears it has spread out because I can tell where the walkthru window has been rubbing on the drivers side windshield more at the bottom than the top. It was rubbed to a razor edge on the bottom! Something I also learned with powder coating is it is like glue. My windshield has two hinging parts where the front glass meets the side pieces and they have to move in order to install the windshield on the boat. I ended up having to strip these pieces and get them re-powder coated with the channels masked off so they could pivot. I'll paint the bare aluminum parts once the windshield is on the boat.

Also if anyone ever needs the screw cover foam and windshield gasket for this year like I did, buy the Taylor Made kit from greatlakesskipper for the 196 Cobalt windshield. It comes with the screw cover foam(1/2"x3/4"), gasket, a few new rubber gaskets, the little plastic windshield standoffs with the rubber tips, new stainless screws, and the turn latches to lock the windshield. Saved me about $50 over buying the foam and gasket by themselves and the extra stuff was a bonus.

98Roo
06-10-2012, 08:17 PM
I was speaking earlier on the floor having a soft spot. I was a little confused as to why since this boat is supposed to have NO wood. Either the trailer had a flat tire where it sat or it was on a hill but I could tell water had sat on the passenger side right behind the observers seat for a while since a little green moss was on the bottom of the red speaker panel and the floor was soft. After a few exploratory holes I just cut the whole soft spot out with intentions to repair it.

The floor doesn't really look like wood but I have no idea what it is. It looks like some kind of composite material sandwiched between fiberglass. Whatever it was, it rotted in between the fiberglass.
http://i64.photobucket.com/albums/h192/redej8/IMG_2995.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_2990.jpg

zabooda
06-10-2012, 09:56 PM
It is some type of fiber board with a lot resin in it. Hard to imagine it rotting. Warping would be a good possibility.

wolfeman131
06-10-2012, 10:22 PM
Wow! What a project! Really going to be fun to watch how it progresses.

98Roo
06-10-2012, 11:31 PM
It is some type of fiber board with a lot resin in it. Hard to imagine it rotting. Warping would be a good possibility.

It was absolutely warped in odd places. There was also some kind of filler like bondo over the deck surface that was about 1/4" thick in places that was cracked and was easy to pry up with a screw driver. We also found the holes in the deck for foam filling covered in this. My guess is it was cracked so badly from being in the sun that water seeped into this "fiber board." Whatever it is, it was completely saturated and soaking wet, so much that I could dig it out with my finger. Also all the foam under the deck was saturated.

wolfeman131
06-11-2012, 12:02 AM
Did you happen to see this thread:

http://www.moomba.com/msgboard/showthread.php?17968-Wet-Sanding-Results

I thought the hard work & chrome decals made Brandon's boat look fantastic! I set up a group buy for the decals at Atlanta Marine, if you're interested.

98Roo
06-11-2012, 12:07 AM
Did you happen to see this thread:

http://www.moomba.com/msgboard/showthread.php?17968-Wet-Sanding-Results

I thought the hard work & chrome decals made Brandon's boat look fantastic! I set up a group buy for the decals at Atlanta Marine, if you're interested.

Yes! I would definitely love to get new decals since I will be removing all the old ones for wet sanding. Not sure yet if I'd want the chrome or just the plain white. I'm kind of digging the new style white decals right now.

wolfeman131
06-11-2012, 12:11 AM
Either would look great against that red.

98Roo
06-11-2012, 12:20 AM
Alright, I finally uploaded some new pics. Viewer discretion is advised for these since they get pretty hairy.

I ended up taking this boat to a complete repair shop over in Alabama. A guy that was a friend of my dads recommended him so hopefully it'll turn out alright. He's been taking a little longer than originally quoted but has been sending me some pictures. Hopefully I'll be picking the boat up next weekend.

Sayonara old floor...
http://i64.photobucket.com/albums/h192/redej8/DSC01699.jpg
http://i64.photobucket.com/albums/h192/redej8/DSC01698.jpg
http://i64.photobucket.com/albums/h192/redej8/DSC01697.jpg
http://i64.photobucket.com/albums/h192/redej8/DSC01696.jpg

98Roo
06-11-2012, 12:21 AM
http://i64.photobucket.com/albums/h192/redej8/DSC01695.jpg
http://i64.photobucket.com/albums/h192/redej8/DSC01694.jpg

maxpower220
06-11-2012, 07:50 AM
Holy Chit, those stringers are very small for a total composite build. I know that wooden stringers were made just like that, but other boat makers have substantially larger stringers when made in composite.

This is quite an extensive project. Go Chrome on the decals, it will really pop on the red and give a modern look to the boat.

Waynes345
06-11-2012, 05:21 PM
Wow. Now I know what's inside my '99. That's unbelieveable. Thanks for posting all the pics. Good luck on putting it all back together.

dusty2221
06-11-2012, 05:57 PM
Incredible! Please keep the thread updated. I love a good project, but I may have sh!t myself when I pulled the floor!

wolfeman131
06-11-2012, 06:00 PM
I may have sh!t myself when I pulled the floor!

Why would pulling the floor make it different than any other day for you?

98Roo
06-11-2012, 06:12 PM
Why would pulling the floor make it different than any other day for you?

Hahaha! Wolfe, I might be interested in some of those decals. Should I just contact Atlanta marine?

wolfeman131
06-11-2012, 11:26 PM
Yep.

Just call Cynde at 678-541-6609 and tell her you want in on the group buy I set up.

moombadaze
06-12-2012, 12:37 PM
great photodocu you are doing, thanks and keep it up. love watching a project like this

98Roo
06-12-2012, 07:04 PM
I meant to post these with the others of the tear down but he's some closer shots of what the inside looked like. Granted I have already cut the mounting "plates" or "pads" out of the transom here.
http://i64.photobucket.com/albums/h192/redej8/IMG_2988.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_2987.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_2985.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_2986.jpg

kaneboats
06-13-2012, 01:01 AM
I had a nightmare once about visiting the planet depicted in the 4th pic.

98Roo
06-13-2012, 09:41 AM
In pics 2 and 4 you can see the outline of where the PO added the steel plate to reinforce just the lower holes. This obviously did not work. The right side had the same plate but you just cannot see a rust outline.

98Roo
06-13-2012, 03:48 PM
Picked up the interior yesterday! Looks like it will reside in the spare bedroom until I get the boat back..

http://i64.photobucket.com/albums/h192/redej8/IMG_3103.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3100.jpg

http://i64.photobucket.com/albums/h192/redej8/IMG_3101.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3102.jpg

dusty2221
06-13-2012, 03:52 PM
Very nice!

And wait, how did no one comment on the monster truck in the background?!?!?! What's the scoop?

98Roo
06-13-2012, 05:00 PM
lol..That was the picture the guy posted on the for sale ad. He owned a towing company .....and a monster truck that he gave rides in at fairs and whatnot. It took me a little while to notice the monster truck when I looked at the ad on oodle. Haha

98Roo
06-13-2012, 09:07 PM
Got a few pics from the repair man on the transom repair. You can see the floor is in but he is waiting on more resin to cover the entire floor. As for the transom, that is a sheet of 3/4" plywood glassed to the transom and one side has an extra reinforcing piece for the platform to bolt to and the other side is prepped for the same. I'm just hoping the gas tank still fits in there with the extra 1 1/2" of wood on the transom.

http://i64.photobucket.com/albums/h192/redej8/DSC01702.jpg
http://i64.photobucket.com/albums/h192/redej8/DSC01700.jpg

Also here's the pylon mount I had made out of stainless. The factory one is just painted steel and was rusted all to hell.
http://i64.photobucket.com/albums/h192/redej8/IMG_3099.jpg

kaneboats
06-13-2012, 10:38 PM
Sweet mount!!! (Wow, I haven't spoken those words since college.)

maxpower220
06-14-2012, 08:36 AM
Any thought as to using Starboard or any other material that is not wood? Also, di he glass the bottom of the floor before installing?

outback98
06-14-2012, 10:59 AM
Wow! Thanks for posting those pics. I thought mine was in bad shape when I got it! Your really going the extra mile. It will be like a new boat when you get her done. Are you going to go ahead and get in painted before assembly?

14884
14885
14886
14887

98Roo
06-14-2012, 12:11 PM
Any thought as to using Starboard or any other material that is not wood? Also, di he glass the bottom of the floor before installing?
Yea, I never gave it much thought about using any other material than wood. I talked to my dad and we were considering doing all the work ourselves, especially after watching quite a few of FriscoJarretts videos on YouTube. Even once I found the soft spot we were just considering repairing that one area. Once we talked to this guy we just decided to take it to him since neither of us had really done any fiberglass work and he said he would uncap it, replace the whole floor, repair the transom, and do all the gelcoat work. He used to be the foreman in the fiberglass shop of some boat manufacturer, forget which one.

He said he would encapsulate the whole floor in resin, especially under the bottom where most people forget or just don't do it. He also replaced all the foam under the deck with closed-cell foam which apparently wasn't used from the factory because all the foam was completely saturated, or it had just broken down and absorbed water.


Wow! Thanks for posting those pics. I thought mine was in bad shape when I got it! Your really going the extra mile. It will be like a new boat when you get her done. Are you going to go ahead and get in painted before assembly?

14884
14885
14886
14887

I plan on wet sanding and polishing the rest of the boat once i get it back. Wow, yours looks great! I just hope mine turns out that well.

bergermaister
06-14-2012, 01:13 PM
If you were ever considering some hidden ballast tanks in the floor, now would have been/would be the time to do it! Talk about custom - could get really creative and do a flood gate system!

98Roo
06-15-2012, 11:32 AM
Progress!!!
I wish these were in better focus but hey, he's a boat repair man, not a photographer.

http://i64.photobucket.com/albums/h192/redej8/floor1.jpg
http://i64.photobucket.com/albums/h192/redej8/transom1.jpg
http://i64.photobucket.com/albums/h192/redej8/Transom2.jpg
http://i64.photobucket.com/albums/h192/redej8/transom3.jpg

98Roo
06-19-2012, 04:39 PM
http://i64.photobucket.com/albums/h192/redej8/carpet2.jpg
http://i64.photobucket.com/albums/h192/redej8/carpet1.jpg
http://i64.photobucket.com/albums/h192/redej8/transom4.jpg

New Guy
06-19-2012, 05:10 PM
Wow looking really nice!

dusty2221
06-19-2012, 07:11 PM
Its really coming along!

motosno963
06-19-2012, 10:53 PM
beautiful..10char

moabbikr
06-25-2012, 09:43 PM
Cant wait for the next round of photos!!

98Roo
06-27-2012, 09:29 AM
So I picked the boat up Friday and worked on it all weekend and a little Monday but got a few things done. Decided to paint the entire bilge with a marine epoxy like what the repair guy painted over the repair with. It looks white but its a light gray marine two-part epoxy from sherwin williams. I figured this would seal anything else up and would be easier to spot any leaks.
I also got all of the decals off the outside and can see what the boat it supposed to look like!
http://i64.photobucket.com/albums/h192/redej8/IMG_3105.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3104.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3110.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3109.jpg

98Roo
06-27-2012, 09:34 AM
I'm not too happy with the red part on the transom since the repair guy just painted and said he couldn't get the red gel coat. We'll see how it turns out but I've also already started sanding that area and when trying to feather it in, it uncovers oxidation and looks like crap. I was just ready to pick the damn boat up since it took him eight weeks instead of the three he originally quoted. I'll probably end up taking it to a local shop to get the gelcoat repaired properly sometime.
Oh yea, here's a few of the transom and the bilge. You can also see the top bracket bolts where he ended up cutting into the extra wood on top of the other wood since those bolts were touching the gas tank and wouldn't let it slide all the way under the back area. The way he did it kind of defeated the purpose of those plates entirely but I guess there's still a 3/4" piece of wood behind that.
http://i64.photobucket.com/albums/h192/redej8/IMG_3108.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3106.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3122.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3123.jpg

motosno963
06-27-2012, 10:52 PM
shes coming along..if u figure out how to fix the gel coat let me know..i have a few cracks around my tower that i would like to fix

98Roo
06-28-2012, 12:00 PM
Well, there's really only one way to do it and that's with gel coat. I might actually try my hand at some gel coat work one of these days since I have a few other places I'd like to get fixed.

I rebuilt the water pump yesterday with a new seal and impeller. It was leaking out of the back of the pump and the old seal was hard as a rock! Put it back together yesterday and fired her up for the first time with the exhaust and all to check for leaks.
http://i64.photobucket.com/albums/h192/redej8/IMG_3120.jpg

Stazi
06-28-2012, 02:13 PM
Looking great. Are you gonna put a tower on it and ballast bags/tanks?

Stazi
06-28-2012, 02:14 PM
PS you should probably replace those bearings in the pump seeing as you already have it all apart.

I'm a bearing engineer, so that's why I'm suggesting you do that.

98Roo
06-28-2012, 04:40 PM
PS you should probably replace those bearings in the pump seeing as you already have it all apart.

I'm a bearing engineer, so that's why I'm suggesting you do that.

Yea I considered that but they spun freely without making any weird noise. I noticed the shaft had a groove worn in it from the old seal and when I ran it yesterday it still drips every now and then from the back even with the new seal. I'll most likely replace the entire pump after this season, or earlier if it starts leaking worse.

98Roo
07-02-2012, 03:30 PM
Getting it all put back together, got the ass end buffed, polished, and got the speedo pickups and hoses installed. Put on new exhaust flappers since there weren't any on it when I bought it. Got the motor cover carpeted with new rubber, bilge pump installed, got all the wire routing figured out, windshield is installed with all new gaskets, screw cover foam, bumpers, latches and siliconed around it on the hull. Also put in all new fresh air/bilge vent hoses and a new battery in a box instead of sitting in a tray.
http://i64.photobucket.com/albums/h192/redej8/IMG_3145.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3142.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3141.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3140.jpg

98Roo
07-02-2012, 03:34 PM
Also started stripping the swim platform to get it ready to polish and put a new pad on.

http://i64.photobucket.com/albums/h192/redej8/IMG_3146.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3152.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3144.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3153.jpg

Stazi
07-02-2012, 03:36 PM
Man that's looking sweet!

bergermaister
07-02-2012, 03:53 PM
Dang - like a BRAND NEW 98 outback!

98Roo
07-02-2012, 04:04 PM
Thanks guys! Hopefully I'll be able to dunk it a little later today to check for leaks and see how it runs.

maxpower220
07-02-2012, 05:29 PM
That thing is looking great. BTW, why not hit the engine with a wire brush and then some black paint. It doesn't take a lot to make the engine look new.

98Roo
07-02-2012, 06:14 PM
That thing is looking great. BTW, why not hit the engine with a wire brush and then some black paint. It doesn't take a lot to make the engine look new.
I'm gonna leave that for a winter project. I'll probably end up taking off the manifolds, pulleys and other peices and get them all powder coated. I also plan to do something different with the dash, like REAL carbon fiber, new gauges and rocker switches instead of turn knobs.

motosno963
07-02-2012, 06:49 PM
shes looking awesome

TRLMoomba
07-03-2012, 01:03 PM
Eric,
Great job!!! And thanks for sharing with all the pictures it is fun seeing your project comeback together. Also fun to see what the inside of the boat looks like. You are definitly going to be someone who can answer alot of questions about these year boats. I thought I had a big project last winter but you really topped that with your project. I know we are all going to look forward to seeing pics of this boat on the water.
Again, Great Job!

98Roo
07-03-2012, 01:54 PM
Josh,
Thanks, I am ready to see it in the water! Especially with all these 105+ degree days we've been having lately.

I got to stick her in the water yesterday, no leaks and she didn't sink but man did it run like complete CRAP. Idle was fine for a bit until it warmed up and then it started surging and would just cut off sometimes. It would run alright up until full throttle where it would die off and then start to backfire. My dad and I both agreed it was a carburetor problem so I took it off the boat yesterday and drain the fuel out of the vents and this is what came out...
http://i64.photobucket.com/albums/h192/redej8/IMG_3150.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3151.jpg

GREEN fuel, water, and crap! I knew the carb looked bad but didn't think it would affect much since it ran fine on the hose. I'm thinking it sat for quite a while with Ethanol gas and really gummed it up. I packed it up and mailed it off today to Carb Junkys in Atlanta for a complete rebuild. I also went ahead and ordered a new distributor cap and rotor, plug wires, and NGK plugs.

98Roo
07-03-2012, 02:04 PM
Also, maybe someone with experience in repacking the prop shaft can answer this. I repacked mine with GFO gore tex packing and followed the guide located here http://www.moomba.com/msgboard/showthread.php?10834-Prop-Shaft-Alignment-Yearly-Maintenance-Item

After I turned it like here with pliers to pack the packing, I loosened it up and tightened the nut hand tight and then put the jam nut up against that. I know the packing says "dripless" but mine doesn't drip at all! I figured it should drip a little for cooling. Should I loosen the nut up some for it to drip? I only ran it for 15 mins or so total and it says not to adjust the nut until after 2 hours of run time but I don't want to burn the packing/shaft up.

maxpower220
07-03-2012, 05:01 PM
I have done a few repackings and I too have had ones that don't leak. I never thought about it being a bad thing. I don't like the thought of a leaking anything on a boat. Give it a little time, if it doesn't leak you are fine. If it drips a few drops per minute, that is OK.

98Roo
07-04-2012, 01:24 PM
I guess I'll just leave it be then and adjust it later if it needs it. Cheers!

motosno963
07-05-2012, 03:35 PM
cant wait to see her done and in the water

Stazi
07-10-2012, 09:45 AM
Josh,
Thanks, I am ready to see it in the water! Especially with all these 105+ degree days we've been having lately.

I got to stick her in the water yesterday, no leaks and she didn't sink but man did it run like complete CRAP. Idle was fine for a bit until it warmed up and then it started surging and would just cut off sometimes. It would run alright up until full throttle where it would die off and then start to backfire. My dad and I both agreed it was a carburetor problem so I took it off the boat yesterday and drain the fuel out of the vents and this is what came out...
http://i64.photobucket.com/albums/h192/redej8/IMG_3150.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3151.jpg

GREEN fuel, water, and crap! I knew the carb looked bad but didn't think it would affect much since it ran fine on the hose. I'm thinking it sat for quite a while with Ethanol gas and really gummed it up. I packed it up and mailed it off today to Carb Junkys in Atlanta for a complete rebuild. I also went ahead and ordered a new distributor cap and rotor, plug wires, and NGK plugs.
Wow, that's nasty. Hopefully the rebuilt carb fixes it!

zabooda
07-10-2012, 08:28 PM
I repacked with graphite impregnated cord back in 2005 and there hasn't been any dripping. Good choice to stay away from wax.

98Roo
07-10-2012, 10:53 PM
Just a small update. I the entire boat is buffed and polished and it looks awesome. Not perfect but it can't be perfect without some gel coat work. I need to pull it out from under the carport and take some pics.
I also decided to go ahead and do a tune up to match the rebuilt carb...which I'm still waiting to get back. The Autolite's I took out weren't in bad shape but they were gapped to .055" which is too big for the carb motor. The factory coil has been replaced at some point with an Accel unit, so that might be why the huge gap didn't seem to affect much. The NGK's I used all came pre-gapped to about .034" so I'll probably just leave them there unless I notice a miss.
You can also see the fuel pressure safety switch on the top left. I guess the stock sensor failed at some point so someone just jumped the wires together. From what I can gather, this switch turns the fuel pump off in the event of low oil pressure.
http://i64.photobucket.com/albums/h192/redej8/IMG_3155.jpg

wolfeman131
07-10-2012, 10:55 PM
You best be working thru the night so that boat will be running this weekend on Sinclair! I want to see it in person.

98Roo
07-10-2012, 11:11 PM
You best be working thru the night so that boat will be running this weekend on Sinclair! I want to see it in person.

I hope to have it on the water this weekend if I get the carb back this week. They claimed a 7-10 day turnaround so I am hoping I get it tomorrow!

I was at the lake this past weekend but we were in my uncle's boat. A '98 black/tan Mastercraft Maristar with a black Samson tower/bimini. You might have seen it out there before.

Stazi
07-13-2012, 08:50 AM
Any updates?

98Roo
07-13-2012, 05:08 PM
Still waiting on the carb...Shop said they were having a tough time cleaning it in the ultrasonic baths and it would probably be Monday..

motosno963
07-14-2012, 09:54 AM
yeaaa that thing look horrible lol

98Roo
07-17-2012, 10:42 PM
FINALLY got the carb back today. Man what a difference. Almost doesn't look like the same carb.

http://i64.photobucket.com/albums/h192/redej8/IMG_3194.jpg

http://i64.photobucket.com/albums/h192/redej8/IMG_3195.jpg


Also got some new bunk boards and got them cut, painted, and ready for carpet.

http://i64.photobucket.com/albums/h192/redej8/IMG_3187.jpg

Got most of the interior back in as well. A few pieces have to go back to get the wrinkles taken out..
http://i64.photobucket.com/albums/h192/redej8/IMG_3191.jpg

spyder
07-17-2012, 11:37 PM
unbelievable work

New Guy
07-18-2012, 03:33 PM
Give it a little bit of time in the sun those wrinkles will probably come out.

ryan_8099
07-18-2012, 04:16 PM
FINALLY got the carb back today. Man what a difference. Almost doesn't look like the same carb.

I don't think anything is going to look the same once you are done, looks awesome! Have really enjoyed the photo updates.

98Roo
07-19-2012, 10:56 AM
Give it a little bit of time in the sun those wrinkles will probably come out.

Thanks, I guess I'll give it some time.

Got the carb on yesterday, had to adjust idle down and got the mixture screws adjusted for best vacuum. She purs like a kitten...at least on the hose. Hopefully I'll be splashing her again tomorrow and might even be able to enjoy it some this weekend at the lake!

ga-lsv05
07-19-2012, 12:00 PM
Awesome job on the resto man hope everything goes well on the lake for ya

2005 mobius lsv 2900lbs ballast liquid audio quad polk tower setup. airboom light bar.

ga-lsv05
07-19-2012, 12:08 PM
Tow her out to westpoint if you need a wing man for her maiden voyage.

2005 mobius lsv 2900lbs ballast liquid audio quad polk tower setup. airboom light bar.

98Roo
07-20-2012, 08:27 PM
Got to put her in the water today at lake Tobesofkee (a tiny lake in Macon, GA) and actually got to wakeboard behind her! The rebuilt carb and tuneup did the trick and she ran GREAT.
I did, however, find a water leak where the exhaust pipe clamps to the tip. It was a pretty good stream from the port exhaust tip. I noticed that the added thickness of the transom drastically reduced the amount of area the rubber pipe can clamp to, there's maybe only about an inch of exhaust tip for the pipe to seal around. The starboard didn't leak at all. I think my solution will just be to order new exhaust tips that, from the pictures, look way longer than the stock ones and they come with flappers. So I'll probably order those soon. For now I'll see how silicone does so I can take her up to Sinclair Sunday.
I also took the speedometers apart because one was sticking and both had dead bugs and crap all in them. Got them moving freely and both seem to work great. I cleaned the lenses, faces, housing and painted the bezels since they were faded to metal.

Here's a few pics right before I left for the lake, at the ramp and the speedos apart.
http://i64.photobucket.com/albums/h192/redej8/IMG_3196.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3198.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3199.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3200.jpg

98Roo
07-20-2012, 08:28 PM
Una mas
http://i64.photobucket.com/albums/h192/redej8/IMG_3201.jpg

zabooda
07-20-2012, 10:10 PM
Just a note. I'm not sure if you remounted the Airguide speedo pickups but the aftermarket pickups is all that is available and they have a different hole pattern. You may want to consider going directly to those as Airguide is no longer around and save from redrilling holes if you glassed that area over. Skidim has the replacements and mine will need to be changed out soon. BTW, the boat looks sharp.

wolfeman131
07-20-2012, 10:23 PM
For now I'll see how silicone does so I can take her up to Sinclair Sunday.

Baker,

I'm really wanting to see your boat! It's looking great. I have to leave Sinclair earlier than usual on Sunday, but if you get out early enough, I will be in the Island Creek area.

98Roo
07-20-2012, 10:36 PM
Just a note. I'm not sure if you remounted the Airguide speedo pickups but the aftermarket pickups is all that is available and they have a different hole pattern. You may want to consider going directly to those as Airguide is no longer around and save from redrilling holes if you glassed that area over. Skidim has the replacements and mine will need to be changed out soon. BTW, the boat looks sharp.

The deed is done and the factory ones are already mounted back. If they break I guess I'll cross that bridge when I get there. Thanks!


Baker,

I'm really wanting to see your boat! It's looking great. I have to leave Sinclair earlier than usual on Sunday, but if you get out early enough, I will be in the Island Creek area.

Wolfe,
If things go as planned, I'll have the leak repaired tomorrow and plan to be up on Sinclair Sunday morning as I'd like to get some skiing in before the water gets choppy. Well, at least I'll try to. It's been a while since I've been on a slalom.

wolfeman131
07-20-2012, 10:40 PM
Let me know. I'll PM you my cell number. Wind has been bad the last few days. We had whitecaps breaking around 2-5 pm today, but it cleaned up after that.

98Roo
07-25-2012, 11:21 PM
Let me know. I'll PM you my cell number. Wind has been bad the last few days. We had whitecaps breaking around 2-5 pm today, but it cleaned up after that.

I was on the way to the lake when I texted you the other day. I left my phone in the car when we got on the water so I didn't have your number but we did some wakeboarding around the island creek area for quite a while Sunday.

The boat ran great with no issues...other than a tiny leak around the exhaust tip. New tips from GLS are on the way, hopefully I'll get them tomorrow. They look quite a bit longer so it should solve the leak. My only hickup was in the evening when I decided to take the boat out of the water. Idled around towards the cove over where the ramp is, throttled up and nothing. Died and wouldn't crank back up. Fuel gauge said I had an 1/8 tank. Turns out the gauge is wrong and the tank was bone dry lol..luckily my cousin was cruising around in his boat and gave me a tow.

I plan to take a lot more pictures of the boat this weekend. Only got a few of me on the board and also on a ski for the first time in close to 10 years. I am still sore 3 days later.

http://i64.photobucket.com/albums/h192/redej8/photo1-1.jpg
http://i64.photobucket.com/albums/h192/redej8/photo-1.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_1986.jpg

98Roo
08-09-2012, 02:46 PM
Here are some final updates probably until I decide which tower I am going to buy and install.
I had an issue where the exhaust hose wouldn't seal to the exhaust tips and had water leaking into the boat when sitting or idling. I ordered some new 3" tips from greatlakesskipper. You can see how short the stock tips were inside the boat. They probably sealed fine without the extra thickness of the transom but since about an inch of thickness was added to the transom and the fact that the tips are actually only 2.75", even on the outside where the flappers connect, the hoses wouldn't seal. The new tips have about 6" for the hose to seal to and are 3" for the whole length. I didn't cut any off which means I'd probably have to remove the tips to take out the exhaust hose but I really don't plan on doing that ever again.

http://i64.photobucket.com/albums/h192/redej8/IMG_3205.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3203.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3204.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3206.jpg

kaneboats
08-09-2012, 02:59 PM
Lookin' good!

98Roo
08-09-2012, 03:22 PM
Lookin' good!
Thanks!

Here's a couple more pics of the boat in the water.. Still waiting on Seadek to make my platform pad....
http://i64.photobucket.com/albums/h192/redej8/IMG_0538.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3202.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_0539.jpg

motosno963
08-10-2012, 05:35 PM
shes looking good.. you wanna come up here and buff out my boat? haha
i like your bench too by the way haha

98Roo
08-12-2012, 03:06 PM
Haha! Thanks! That's our "old dock" that needs to be redecked and apparently the bench needs redecking too haha!

deerfield
08-12-2012, 10:01 PM
98Roo - I admire your talent and taking some risk on this project boat. Nicely done. - Deerfield

98Roo
08-29-2012, 06:49 PM
Just a small update. Finally got my SeaDek platform pad. Color is storm grey over black. I love it!
http://i64.photobucket.com/albums/h192/redej8/IMG_3231.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3229.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3230.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3232.jpg

98Roo
08-29-2012, 06:50 PM
http://i64.photobucket.com/albums/h192/redej8/IMG_3237.jpg
http://i64.photobucket.com/albums/h192/redej8/IMG_3238.jpg

EricU
08-29-2012, 07:46 PM
Just a small update. Finally got my SeaDek platform pad. Color is storm grey over black. I love it!
http://i64.photobucket.com/albums/h192/redej8/IMG_3231.jpg


Your boat, progress pics and story are fantastic!!
Did you get that SeaDek from thier online store?
Do they charge extra for the logo?
Again, GREAT Job!!!

Eric.

maxpower220
08-29-2012, 09:15 PM
That's an old school looking Connelly ski.

98Roo
08-30-2012, 08:09 AM
Your boat, progress pics and story are fantastic!!

Did you get that SeaDek from thier online store?
Do they charge extra for the logo?

Again, GREAT Job!!!

Eric.

Thank you! It's been a lot of work but it's paying off on the weekends now! I ordered the pad directly from SeaDek. Just call and you'll talk to Susan. I think the pad drawing they used was for a 2000 model but the measurements she gave me matched my platform. The logo was $30 extra so I believe I paid $270 total.


That's an old school looking Connelly ski.
It's actually just a new combo I picked up from Academy Sports for like $65 on sale. I'm no pro so the slalom is good enough for my low skill level for now.

moombacraze
08-30-2012, 08:48 AM
The SeaDeck looks great in the grey and black! The boat has turn out amazing! Great work. This has been a fun thread to follow! Thanks again.

kaneboats
08-30-2012, 09:33 AM
Yea, I've really enjoyed following it too. I had a 2000 Outback and loved it but we just outgrew it. 8 people every time out plus surf bags on the floor was just too much. But, I sure miss the speed sometimes. She's fun to drive, ain't she?

BGeorge01
08-30-2012, 10:43 AM
Very Nice man, Congrats on all of the work!! The pad is next on my list also, was it easy to put on?

98Roo
08-31-2012, 06:23 PM
The SeaDeck looks great in the grey and black! The boat has turn out amazing! Great work. This has been a fun thread to follow! Thanks again.
Thank you!

Yea, I've really enjoyed following it too. I had a 2000 Outback and loved it but we just outgrew it. 8 people every time out plus surf bags on the floor was just too much. But, I sure miss the speed sometimes. She's fun to drive, ain't she?
She is very fun to drive and pretty quick! Over the winter im going to add a tower so I can actually accommodate more people when towing someone.

Very Nice man, Congrats on all of the work!! The pad is next on my list also, was it easy to put on?
It was super easy to install. I watched the seadek vids on YouTube before I did it.

kaneboats
08-31-2012, 11:57 PM
I put a tower on mine. My albums show pics of it in my living room. I was a lot more excited than Mrs. Kane was-- she actually cried when I brought the "junk" Moomba (Outback LS) home even though I spent $10,500 on it.

98Roo
05-28-2014, 11:01 PM
Back from the dead!!............with a quick update.

Decided on a New Dimension Tower w/ Bimini last spring and enjoyed it all last summer. Just can't seem to find any in the lake...

I have another project I'll share once I get the rest of the pics sorted and uploaded to Photobucket but I do have a couple I'll leave as a hint...

http://i64.photobucket.com/albums/h192/redej8/iphone500_zps14789a0d.jpg (http://s64.photobucket.com/user/redej8/media/iphone500_zps14789a0d.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone501_zps3c7bab3d.jpg (http://s64.photobucket.com/user/redej8/media/iphone501_zps3c7bab3d.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone502_zps8d51ffd7.jpg (http://s64.photobucket.com/user/redej8/media/iphone502_zps8d51ffd7.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone503_zpsea3d4eb2.jpg (http://s64.photobucket.com/user/redej8/media/iphone503_zpsea3d4eb2.jpg.html)

98Roo
05-28-2014, 11:03 PM
With Bimini..

http://i64.photobucket.com/albums/h192/redej8/iphone504_zps1a0942ed.jpg (http://s64.photobucket.com/user/redej8/media/iphone504_zps1a0942ed.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone505_zps83c06108.jpg (http://s64.photobucket.com/user/redej8/media/iphone505_zps83c06108.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone506_zpsa6f4d918.jpg (http://s64.photobucket.com/user/redej8/media/iphone506_zpsa6f4d918.jpg.html)



And as for the hint on the other project..Thanks to Great Lakes Skipper for having too much crap I don't need....

http://i64.photobucket.com/albums/h192/redej8/IMG_3328_zpsb8500a6e.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3328_zpsb8500a6e.jpg.html)

sivs1
05-29-2014, 08:24 AM
looks great already, can't wait to see the rest. Why don't they have a movie called the "Boat Money Pit"? that's where all mine seems to go!

kaneboats
05-29-2014, 12:55 PM
She still looks fantastic. Now get busy on the trailer (after the dash project). :cool:

kelauben
05-31-2014, 10:20 AM
Hey there. I was admiring your work as I prepare to go much of the same on my 98 Outback. I'm going to start with some gelcoat oxidation fixes. Just curious, when you did your initial wet sanding and buffing that was at the beginning of your thread, how did you get around the trailer wheel fenders and side guides? Did you move the boat on the trailer or raise it up and move the trailer? The only other thing I can think of is good old fashioned elbow grease and do the sanding and buffing by hand.

Thanks

Karl

98Roo
05-31-2014, 02:23 PM
I got everything I could around the fenders. I was able to get by the guide posts with everything fine, just had to polish from both sides of them. I put it in the water for a test and when I loaded it on the trailer I left it off the bow roller enough (like 2 ft)to get the sides of the boat behind the fenders. Luckily my test lake wasn't far from home, it's weird pulling a boat hanging off the trailer. When done I just winched it back up snug. Kind of a pita but if you want to get everything... I suppose you could also tie it it a tree or something and pull the trailer out from under it.

zabooda
06-01-2014, 01:00 AM
Wow, great look. I copied all your pics a while back in case I upgrade mine. The tower is so much better than the stock one. Was the dash made from a mold of your old one? I like the new gauges. I have to say that my fiberglas is holding up real well with the metal-flake finish and all. Some people think it is a newer boat.

jmb
06-01-2014, 06:55 AM
Only takes a few minutes to unbolt and take the fenders off.

kelauben
06-01-2014, 08:04 AM
Only takes a few minutes to unbolt and take the fenders off.

They come off?!? Lmao! I can't believe I didn't check to see if they did. That's funny (embarrassing). Now if the guides came off too, I'd be set. I'm sure I can move the boat back a little to get to those areas. Any suggestions on how best to go about that?

Thanks

K

jmb
06-01-2014, 09:55 AM
I don't know about yours, but my guide poles are just pinned in place. I just remove a D ring and they come out. Yours might be different

liquid_acid
06-01-2014, 10:54 AM
Looks great.


Sent from my iPhone using Tapatalk

98Roo
06-01-2014, 01:19 PM
Few more crappy shots of the tower. I'll have to get the gf to drive it out so I can get some better pictures.

http://i64.photobucket.com/albums/h192/redej8/iphone584_zpsd5d85e41.jpg (http://s64.photobucket.com/user/redej8/media/iphone584_zpsd5d85e41.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone585_zpsa4126fed.jpg (http://s64.photobucket.com/user/redej8/media/iphone585_zpsa4126fed.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone586_zpsd82725de.jpg (http://s64.photobucket.com/user/redej8/media/iphone586_zpsd82725de.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone582_zpsba5edd93.jpg (http://s64.photobucket.com/user/redej8/media/iphone582_zpsba5edd93.jpg.html)

98Roo
06-01-2014, 01:20 PM
http://i64.photobucket.com/albums/h192/redej8/iphone587_zps6cf8ee59.jpg (http://s64.photobucket.com/user/redej8/media/iphone587_zps6cf8ee59.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone583_zpsdfc909f7.jpg (http://s64.photobucket.com/user/redej8/media/iphone583_zpsdfc909f7.jpg.html)

kelauben
06-01-2014, 01:24 PM
I don't know about yours, but my guide poles are just pinned in place. I just remove a D ring and they come out. Yours might be different

I checked. Mine are welded on so no removing them. I think I've figured out a way to back it off the trailer 6" and I'll be good. But thanks for the suggestion.

K

98Roo
06-01-2014, 01:31 PM
Wow, great look. I copied all your pics a while back in case I upgrade mine. The tower is so much better than the stock one. Was the dash made from a mold of your old one? I like the new gauges. I have to say that my fiberglas is holding up real well with the metal-flake finish and all. Some people think it is a newer boat.

The dash I bought from GLS. I wanted newer, better looking gauges and rocker switches instead of the turn knobs. After pricing everything individually, it made more sense to go with that entire gauge/switch package with all wiring as well. GLS only pictures the gauges and switches. It was only when I received it that I found it was the entire dash. I think it's out of a '03ish boat if I'm not mistaken.

I thought about cutting mine out and making the new one fit in there for about 3 mins, and then figured it would be too much trouble and time. So I decided to just do something with my original panels. The original stuff had that fake, crappy carbon fiber sticker type deal on it...so I decided to just make new carbon fiber pieces using the old parts as to make molds..

http://i64.photobucket.com/albums/h192/redej8/IMG_3341_zps3c35992d.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3341_zps3c35992d.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/IMG_3369_zps23860a13.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3369_zps23860a13.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/IMG_3374_zpsede344b3.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3374_zpsede344b3.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/IMG_3376_zps30770771.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3376_zps30770771.jpg.html)

98Roo
06-01-2014, 01:45 PM
http://i64.photobucket.com/albums/h192/redej8/IMG_3390_zps27ebd377.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3390_zps27ebd377.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/IMG_3391_zpsee4affa0.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3391_zpsee4affa0.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/IMG_3397_zps74065ef8.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3397_zps74065ef8.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/IMG_3398_zpsc1b2c5eb.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3398_zpsc1b2c5eb.jpg.html)

98Roo
06-01-2014, 01:46 PM
http://i64.photobucket.com/albums/h192/redej8/IMG_3400_zpsf7fdff9f.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3400_zpsf7fdff9f.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/IMG_3404_zps67a05524.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3404_zps67a05524.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/IMG_3411_zps4cffc3a6.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3411_zps4cffc3a6.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/IMG_3413_zpsbfa61cce.jpg (http://s64.photobucket.com/user/redej8/media/IMG_3413_zpsbfa61cce.jpg.html)

BGeorge01
06-01-2014, 03:16 PM
http://i64.photobucket.com/albums/h192/redej8/iphone587_zps6cf8ee59.jpg (http://s64.photobucket.com/user/redej8/media/iphone587_zps6cf8ee59.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone583_zpsdfc909f7.jpg (http://s64.photobucket.com/user/redej8/media/iphone583_zpsdfc909f7.jpg.html)


Is that captain chair a swivel?? Wanna share your design for that? I've been looking for a way to get mine to be able to do that.


Sent from my iPhone using Tapatalk

98Roo
06-01-2014, 10:48 PM
Just sandwiched a $10 seat swivel from Academy Sports between the slider and seat. :) Took a little ingenuity but overall wasn't too bad. It's not the most stable, the chair can rock around on it pretty easily and I'm not a fan of not being able to lock it. My plan is to grab a new swivel/slide pedestal from GLS eventually.

98Roo
06-02-2014, 01:19 PM
Only takes a few minutes to unbolt and take the fenders off.

Not possible with my trailer. Fenders and guide posts are a welded part of the trailer.

jmb
06-04-2014, 09:02 PM
Well, that sucks. I got nothin I guess. Mine all comes apart.

98Roo
06-10-2014, 10:19 PM
So I noticed a had a couple soft spots on the swim platform and also noticed it would drip water out of a few places thru the fiberglass/paint for a few days on the trailer. Would run out even more if I took it off and set it upright and pushed on a few places. After probing with a small screwdriver I figured out it was soaked on the inside....So I started tearing into it thinking I could just replace the rot with new wood, but ended up tearing it all out. It was wet in places almost all the way to the middle of the platform.

In the process I found it was balsa cored which lead me to realize what the FLOOR OF THE BOAT is made out of. BALSA sandwiched in fiberglass.. So much for "wood free." I guess if you don't consider balsa to be wood then yes.
It was easy to get the wet stuff out but the stuff that was completely dry was pretty tough to get up. Just used a Dremel to cut small squares and chiseled them out.

http://i64.photobucket.com/albums/h192/redej8/iphone635_zps36d6131f.jpg (http://s64.photobucket.com/user/redej8/media/iphone635_zps36d6131f.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone636_zpsaa29f7d2.jpg (http://s64.photobucket.com/user/redej8/media/iphone636_zpsaa29f7d2.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone637_zpsbdef7452.jpg (http://s64.photobucket.com/user/redej8/media/iphone637_zpsbdef7452.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone639_zpsd1a5ecb9.jpg (http://s64.photobucket.com/user/redej8/media/iphone639_zpsd1a5ecb9.jpg.html)

98Roo
06-12-2014, 08:53 AM
Here it is completely cleaned of all old wood, sanded and ready for new fiberglass and wood, And then putting everything back together. I made my own "peanut butter" by cutting up chop strand mat to tiny pieces with scissors and mixing it in with the resin. Worked great despite not using any filler or thickener like cabosil. I used it to bond the wood to the platform and then used it around the edges to fill the gap, along with some left over tiger hair that came with my wakeboard tower.


http://i64.photobucket.com/albums/h192/redej8/iphone641_zpsfd7bd455.jpg (http://s64.photobucket.com/user/redej8/media/iphone641_zpsfd7bd455.jpg.html)

Sticking it down
http://i64.photobucket.com/albums/h192/redej8/iphone642_zpse9afa648.jpg (http://s64.photobucket.com/user/redej8/media/iphone642_zpse9afa648.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone644_zps6d5421be.jpg (http://s64.photobucket.com/user/redej8/media/iphone644_zps6d5421be.jpg.html)

98Roo
06-12-2014, 09:00 AM
I also reused the stock plastic blocks where the brackets screwed in. Just used the peanut butter to stick them and then went over with mat and cloth. Also when I reinstalled the brackets, I squirted marine epoxy into the screw holes and when around each one before sticking the brackets on and tightening to make sure no water got inside. This is how the stock platform rotted. The screws holes went thru the plastic into the wood. There was no sealant under the brackets or screws so water eventually made its way past the screws and into the balsa.

One downside to using plywood instead of balsa is how heavy this thing is now. Much heavier than before but hopefully it will last.
The last thing I need to do is paint the underside. Guess I'll see how well my leftover epoxy paint sticks to poly resin after sanding.

http://i64.photobucket.com/albums/h192/redej8/iphone646_zps4129f01e.jpg (http://s64.photobucket.com/user/redej8/media/iphone646_zps4129f01e.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone647_zps54b8d2e9.jpg (http://s64.photobucket.com/user/redej8/media/iphone647_zps54b8d2e9.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone648_zpsc1c645d8.jpg (http://s64.photobucket.com/user/redej8/media/iphone648_zpsc1c645d8.jpg.html)

http://i64.photobucket.com/albums/h192/redej8/iphone649_zpsd0b41435.jpg (http://s64.photobucket.com/user/redej8/media/iphone649_zpsd0b41435.jpg.html)