My New 1987 Wellcraft 210 Classic Project

[ayaresr]

Few weeks ago I purchased a 1987 Wellcraft 210 Classic. Its setup with a 5.7 V8 and Alpha I drive. This is my first boat. At time of purchase I knew it needed a new floor, rewiring of basically all of the electrical accessories (lights, depth finder, etc), as well as straightening out incorrectly wired engine gauges. The seats are also in pretty rough/dry rotted shape. Wasn't too worried about the wiring, as electrical is kinda my thing. With some online research, I feel pretty confident about redoing the floor. After taking it out for a run, I found a major oil leak, and a leaking water circulation pump. The prop also seemed to have been spun, as much over a crawl I was losing propulsion and the engine was revving way up.
Since then, I have torn into the motor, replaced the gasket and seals on the timing cover (oil pan and shaft seals), installed a new water pump and hoses, and gotten my hands on a gently used stainless prop. The outdrive oil has now been changed, which didn't look all that bad to begin with, and no signs of water in the oil. Now looking forward to another trial run to see how the repairs hold this week. Depending on how it runs and the shape the stringers are in, that will probably determine whether or not I end up pulling the motor to clean more of it up and paint it or if I just leave it.
Fuel gauge wiring has been straightened out, guy had the sender and ignition + reversed, still need to look into the oil pressure gauge, temp, and speedometer-none of which appear to be functioning as of right now. The lighting (of which only the bow light was found to be connected) needs fixing, and I would like to start from scratch with a new fused distribution block and go from there with that. I will eventually be looking to install an AM/FM stereo, as well as mounting a new VHF.
As for the floor, there's several areas that are in very bad shape. After looking closer, it would appear someone has already put down a second band-aid layer of standard (not marine or even pressure treated) plywood and left that unsealed and exposed...understandably both layers have failed. I plan to rip up all the flooring both the deck and in the cuddy area, check the structure below that, and replace it all with more appropriate materials.
So for now, while I get my projects in order, I'm open to any suggestions, tips and tricks, and of course any insight from fellow owners of this model.
Here's a few pictures, and I'll keep the threat updated with my progress...thanks for reading and sorry for being so long winded. (I will resize the pics and insert them again later, the were way too big for pasting in the thread, so for now here's the links)
Ryan
http://www.ayares.com/boat/pics/boat.jpg
http://www.ayares.com/boat/pics/boat2.jpg
http://www.ayares.com/boat/pics/boat3.jpg
http://www.ayares.com/boat/pics/boat4.jpg

 

[Bob_VT]

Re: My New 1987 Wellcraft 210 Classic Project

Welcome to iboats. You have a very nice boat and you are about to become very intimate with the restoration section. You will see that 95% of our projects are done right and we too hate band-aid repairs.

Read through the completed project section and read this thread (as homework) which will prepare you for the quest http://forums.iboats.com/showthread.php?t=234392

Just about every make of boat has been or is in progress of being restored here. iboats has a great store (tab located on top)for supplies and advice you will be amazed at.

There is even an electronics section to re-wire everything the right way and an I/O forum which is the best available!!!

 

[ayaresr]

Re: My New 1987 Wellcraft 210 Classic Project

I will say I have been doing quite a bit of reading through the various sections of the forum for probably the last month. This is the first I have seen that linked thread, from a quick preview that looks very detailed, and I will definitely be giving that a thorough read.
Thanks for the welcome,
Ryan

 

[yoyins69]

Re: My New 1987 Wellcraft 210 Classic Project

dude very nice boat I got a similar boat and I too have to change the floor and a couples of things but its all right. this is my first boat too we are even and dude they run great so I hope you enjoyed working on it

 

[prolinews]

Re: My New 1987 Wellcraft 210 Classic Project

Anything and everything you could do to your boat is covered on this site. We get hung up on resin choice sometimes but the fundamentals are the same. In the few years I've been on here it is safe to say 99 percent of the boats rebuilt on here are better than the day the left the factory.

 

[ayaresr]

Re: My New 1987 Wellcraft 210 Classic Project

yoyins69, thanks for the kind words, I have enjoyed what work I have done thus far. I always enjoy hands on work and tinkering with things, and I'm always up for learning to do something new, so I say bring this thing on. I bought it knowing it needed work, and that the season was going to be wrapping up, with a goal to be water ready for the spring, so I am going to pace myself on the floor work, do all the research I can and do this right so I only have to do it once. As of now I have most of the engine issues worked out, except for a few gauges still needing rewiring. As for the rest of the wiring, I've done some of my own vehicles as well as some work on emergency vehicles in the past, so I should be able to hammer that part out rather fast once I sit down and figure out a plan of attack.
prolinews, from what I have seen, I would have to agree with 99% coming out better than new, and I look forward to hopefully joining that percentage once my work is finished.
Ryan

 

[ayaresr]

Re: My New 1987 Wellcraft 210 Classic Project

We had very nice mid 70's temps here Thursday and very calm water, so I took the boat out for the first time since fixing the engine. Starts right up (better than my truck haha) and runs beautifully. Ran for about an hour with no problems. Found a few other things needing some work (speedometer pickup tube needs replacing), so I have a better idea what else needs work and a few things I may want to change. This was probably one of the last decent days we will get this winter, so now its time to get serious and get all the work done so its like new for spring. Can't wait and already wanting it to be Spring. More to come as I get to work...
Ryan

 

[ayaresr]

Re: My New 1987 Wellcraft 210 Classic Project

Finally got all of the wiring straightened out on the gauges and got them all working. Mounted a new pickup for the speedometer, and wanting to test that out, decided for a quick ride today. Got to the ramp, went to start the motor, and it just cranked and cranked. It was a slow crank, so thinking low battery, I lifted the engine hatch to throw the battery switch to battery #2, at which point I found the engine compartment was full of smoke. After immediately turning everything off and shutting off the batteries, as well as making sure I had no fire, I started looking for the source (obviously now with no intention of going out today as we didn't feel like swimming). I traced it to the area of the alternator, left it at that and trailered the boat. When we got home I messed with it a bit more and there is a sparking noise from that area, but it seems to be coming from inside the alternator as opposed to the connections on it. Wondering if the windings are shorted or something...anyone with any suggestions? What stumps me is it ran fine on the hose in the driveway yesterday when I was testing the gauges out.
Thanks and sorry for being so long winded!
Ryan

 

[ayaresr]

Re: My New 1987 Wellcraft 210 Classic Project

Finally getting around to repairing the floor and doing the seats. If anyone has any info on the original seating layout I would be interested. From what I have been able to find online, it looks to me that this originally came with two sets of back to back seats, and then had two seats (one on either side of the engine) up against the transom. In that setup, I believe the vinyl cover at the transom was maybe 6" deep or so and the engine cover was fairly deep. I think at some point, someone modified my setup. The vinyl cover on mine is maybe 24-30" deep now, and you can see where the engine cover was cut, just beyond the cupholders. The rear seats are gone, the back is more like a sundeck now, and its just got the two back to back seats. I can get pics of this tomorrow. My next question would be thoughts on a new layout. What I am considering after the floor work is done is this. Two seats to replace the back to back, new ones facing forward only. Then along the back, a wrap around that would go completely across the back, and come out a seats width along each side of the boat. With this, I would do away with what is left of the engine cover, and have to come up with some type of removable design for the rear seat for engine access. I was thinking some kind of latch and hinge setup so the seat would fold up out of the way off to one side on hinges. I can draw this out and post if need be. Looking for any thoughts on that, and I feel like I'm rambling now, so I will leave it at that.
Thanks, Ryan

 

[mikezohsix]

Re: My New 1987 Wellcraft 210 Classic Project

check out the completed projects section, there are plenty of pictures of different types of boats for layout suggestions.

come on spring

 

[ayaresr]

Re: My New 1987 Wellcraft 210 Classic Project

Figure its been a while since an update, so here's where I'm at. The interior has been gutted, seats, floor, flotation foam, and wrapping up gutting the cuddy now. All of the foam was soaked, and water could be squeezed out by hand. Some, but not all of the stringers are rotten. Both of the engine mounts are wasted, rotten almost throughout. The deck hatch over the cuddy was leaking, seals were shot, and the bow hook looks like it may have also leaked, as the metal behind it was rusted and flaking. Because of this, all of the carpeting inside was ruined and somewhat moldy. I've got a bit more tearing out to wrap up this week, plywood is drying out in the garage, resin on hand, and my fiberglass should be here tomorrow. I'm looking forward to starting the process of putting things back together. For now, here's a few new pictures, I've got more, but working on setting them up as a web page and will link to that when I'm ready.

http://www.ayares.com/boat/pics/052710boat1.jpg
http://www.ayares.com/boat/pics/052710boat2.jpg
http://www.ayares.com/boat/pics/052710boat3.jpg
http://www.ayares.com/boat/pics/052710boat4.jpg
http://www.ayares.com/boat/pics/052710boat5.jpg
http://www.ayares.com/boat/pics/052710boat6.jpg
http://www.ayares.com/boat/pics/052710boat7.jpg
http://www.ayares.com/boat/pics/052710boat8.jpg

Ryan

 

[ayaresr]

Re: My New 1987 Wellcraft 210 Classic Project

Moving forward on my project, I have a few questions...

1) On the stringers, pretty much all of the tops are trashed, most are alright about halfway down or so. Would it be considered acceptable (aka structurally sound) to take them down to good wood, and splice new in where needed, instead of taking it all the way down to the hull? My thinking in this is it won't take as long as if I had to bed them into the hull from scratch. Am I correct in thinking splicing and glassing will go quicker than bedding new and glassing, or am I going to make more work for myself this way?

2) Attaching the new deck to the stringers...What's the best way to go about this, keeping as much strength as possible, while making this thing as watertight as possible? Some type of adhesive or resin on the stringer tops as I go I would imagine?

3) Am I correct in thinking I can just seal all sides of the plywood for the deck with resin before install, or does that need to have mat too?

4) Flotation Foam...If I keep my batches very small, can I pour the foam BEFORE I put down the deck, and cut down any overfill, or am I better off laying the deck, drilling the holes, and then doing my pour? I'm just having a very hard time coming to terms with cutting holes in my newly sealed deck. I have seen from what I took out what improperly sealed holes lead to (old deck rotted out from deck plates first). I realize I could seal them better than the old, but still, I really don't want any chance for new problems. Will shaving down the overflow open the new foam to water intrusion?

5) Last one...for now. I am starting to explore my options for seating, and have been considering 2 pedestal seats up front in place of the back to back's I had, and then want to build a bench across the back. This would also fix my engine access problem (the way the last guy put this back together I had to sawzall the plywood in half that he had across the front part of the engine compartment, it couldn't be removed without removing the back to back seating first.) Page 3 of this thread ---> http://forums.iboats.com/showthread.php?t=369197&page=3 <--- is pretty much exactly what I want the rear bench to look like, except I was thinking of wrapping the seats up each side far enough to sit sideways with your feet up. Any suggestions on how I could make this removable without too much difficulty? I like the hinged idea in that thread, but I'm not sure that will work with my wraparound. I was thinking a setup of either latches, or hinges one could knock the pins out of to take the seats out for access, but I also don't want the seats rattling like crazy every time the boat is on the water.

Sorry for being VERY long winded, and appreciate any input.
Thanks, Ryan

 

[ayaresr]

Re: My New 1987 Wellcraft 210 Classic Project

Bump...no suggestions?

 

[dezperado]

Re: My New 1987 Wellcraft 210 Classic Project

Hello from the Netherlands

I have same boat and when I bought it the floor was also rotten and renewed it completely Here the pics http://www.flickr.com/photos/dezperado/sets/72157625321176457/
I used epoxy resin and glasfibre. Is more flexible then polyester but a lot more expensive and every layer needs 24 hours to dry. Beware of poisonous fumes as it does not smell but is dangerous for your health. so cover your mouth or work outside.

Before this boat I had a sort of copy of a Glastron ( Hammond Texas) great boat but floor got loose because of big waves in Italian lakes. Fixed it with epoxy and bought this one. Is great boat. The last 2 years they stole my high five prop. Twice.

I will sell my boat in spring as I am getting too old for all repairs and maintenance. But is best boat I ever had. Esspecially with high waves.
Dont fill the floor up with foam. Just a bit to keep the fueltank in place. Dont use screws but glue it all together with epoxy and will last forever.
The wood of the engine support was also like a sponge and I glued 2 pieces together of tropical hardwood with some wooden pins. If you have more questions you can mail me
h.meeuwsen at gmail dot com

 

[ayaresr]

Re: My New 1987 Wellcraft 210 Classic Project

Appreciate the link to the pics. Very nice work on the rebuild, left me with some new ideas for when I start putting things back together. Hopefully that will happen this spring...this hasn't moved along quite as fast as I would have liked, but I'll get there. I envy your shop space there, as all of my work is outdoors right now. I've got new engine mounts in, just haven't had warm enough weather to do the fiberglassing lately. I'll try to remember to get some new pics of my work posted here shortly.
Thanks again,
Ryan