Starting new project 1973 Sea Ray 240 SRV

[sheboyganjohn]

Thanks for the prayers. Slowly recovering. My back is doing just fine right now but it is a slow process regaining feeling in my foot, and butt. Most of the sensation has come back to the skin but the muscles in the foot are still cramped up most of the time. I have also lost a lot of strength. I tried to go up on my toes and I could barely get my heel off the floor while using my arms on two chairs to help. I could stand on my toes on one foot easily before all this. I have the follow up with the surgeon on the 21st so I will not be doing much with a 10 lb weight limit and no twisting or bending. Been slowly taking care of things to get ready for duck hunting. I should have my restrictions lifted the week before the season.

 

[sheboyganjohn]

I'm baaaack. Back is in the best shape its been in years. I never realized how much pain I was in until after I was all healed up. The feeling in my foot is still on its own time frame, but its about 80% right now.

As for the boat, I pulled the rebuilt engine that was having blow by and replaced it with another rebuild. This time I started with a block that was never bored and had great cylinders. Bought it from an outfit that scraps boats and sells the parts. Rebuilt both carbs and finishing up some other small engine items. Plan is to get the orgiinal engine fired up and running first. Then I will get the rebuilt one up and running for cam/lifter break in in the yard. I will then take it out to a local lake for some running under load.

I will get some pictures as I get the fuel tank put in over the next few days.

On an unrelated note, I am scrapping the dory. No one ever wanted to go hunting so I sold the motor and pulled all the usable parts. Hull goes to the dump next week and the trailer will then be sold. I will be nice to have some room for once.

 

[Woodonglass]

Glad you're all better! I may be facing my 4th Neck/Back surgery in a few months. Getting Spinal Steroid injections now to see if that'll work. My right arm is 75% numb so hoping that'll improve too.
You have to be a Tough son of a gun to get old!!!!

 

[sheboyganjohn]

Woodonglass, that does not sound like fun. I was lucky, if getting back surgery is lucky. My surgery required a neurosurgeon and it was done at the medical college so it was a top surgeon with top equipment. My wife works in the medical field and would not let any of the surgeons she knows from our town even look at me, let alone do surgery.

Got the rebuild engine through the cam break in session. The other engine I cannot even get a spark out of it. I think I am going to move the Pertronix unit over and see if that works. I plan on ordering another one so I can have both engines running on the same ignition. Also looks like I missed some wires when I wired the second one in. Doesn't surprise me since I was doing that work right before my back blew out. It is amazing the dumb decisions you make when working in pain.

I will get some pic's up tonight.

 

[sheboyganjohn]

OK, question time. If you look at post 22 you can see how the floor was built over the fuel tank. There is a section of plywood with the teak grating over the top. Outside of looks, does anyone see any reason not to just put the plywood flush to the deck and skip the teak boards? There is almost zero room under the teak. Might be able to fit a rod without a reel on it and that about it.

 

[Woodonglass]

Does the Teak serve any purpose other than Cosmetic? If NOT then If you don't Use it...Lose It!!!

 

[sheboyganjohn]

I can't find any function for it so I am loosing it, or at least using it as spare wood for other parts on the boat that are teak. There is no way I am going to toss any teak, to dang expensive.

On to the update. I have made a box to hold the fuel tank. It will go down inside the hull on top of the supports I made out of a plastic board, might be starboard. I got it as part of the stuff I picked up from Palmer Johnson so I'm not sure. Anyhow I made it 3% larger to accommodate the expansion of the plastic tank. Painted it green since I had a bunch of green oil based paint I wanted to get rid of.

 

[sheboyganjohn]

Here is the fuel tank in place. I will caulk the edge of the angle iron so that water cannot collect between it and the stringers.



Here are a few pic's of the cover in place.

Hoping to get it in the water for the first time this weekend. All dependent on how the weather is the rest of the week so I Can get the fuel plumbed in

 

[sheboyganjohn]

Fuel tank is plumbed in, just need to wire the level sender. Also replaced the three thru hulls for the cabin. Had to do a bunch of sanding first since the thru hulls were painted over with bottom paint. I plan on sanding all the old bottom paint off so I don't want to remove them again for sanding. Ran the fuel line out to the motors but the suction side of the fuel pumps point towards the rear. I am going to install a 90 on each one so the fuel hose does not need to bend around in a 180. Still running on schedule for a Saturday 1st launch as long as the outdrive seal kit and Pertronix kit both show up before then.

 

[sheboyganjohn]

One fun thing I forgot to post. I was fixing some oil leaks on the oil pan of one motor and found I forgot one oil pan screw. Of course it is the one behind the starter and the only way to get to it is to remove the starter. the only way to remove the starter is to remove two of the bolts holding the starter shield on. So I need to remove four bolts and pull the starter to install one 1/4 20 bolt.

On a related note, I was told to spend the money and get the one piece oil pan gasket and don't worry about putting any sealant on it. Guess I should have went with my gut and used some sealant.

 

[sheboyganjohn]

Made more progress tonight. Dropped the starter and went to replace the missing screw to find out there was one in there, it was just shorter then the others and you could not see the end sticking out of the block. So I just sealed up the seam real well. Installed the 90's on the fuel pumps and got the fuel lines plumbed in. Ran the wire for the fuel level sender. Installed the intakes for the bilge vents. Found the original exhaust blower was shot so I need to pick one up tomorrow. Ignition module showed up so installed that too. It is slowly starting to feel like I might actually get it launched.

 

[sheboyganjohn]

Tonight replaced the old push button tilt and trim switched with toggle switches. Installed the bilge blower and have it wired in. Tomorrow is bilge pumps, some switch wiring, lights, reinstall the starter on the port engine, rewire trailer, and cap unused thru hulls in the side of the boat. Then it is off to the boat launch, depending on weather.

Carpet is on its way. Tonight I ordered the material to replace the Bimini top, the vinyl to do the side panels and the interior cushions, and some other material to make covers for the jet ski's. Yes I decided we did not have enough water crap and bought two jet ski's over the winter. Had never been on one before, but dang are they fun. At least one of them was water ready so we have used that one. The other is basically ready now after an impeller wear ring and a starter rebuild. I also want to replace fuel lines on it, but may hold off and just do that next year.

 

[sheboyganjohn]

Holly heat batman. This 110 heat index weather can take a hike. Gave up about noon. Too dang hot under the high sun since I am out in the open. Got the starter in, bildge pump wired, last of the air duct installed for the blower and drilled and anchored the front motor mounts for each engine. Glad I remembered that one. I will try to get at it again in the evening.

 

[Tnstratofam]

Looks like you are really knocking things out. Working in the heat really sucks the energy right out of me. I have to push through it when I'm at work, but when I'm working around the house or outside in the garden I take lots of breaks.


Looking good.:encouragement:

 

[sheboyganjohn]

Looks like you are really knocking things out. Working in the heat really sucks the energy right out of me. I have to push through it when I'm at work, but when I'm working around the house or outside in the garden I take lots of breaks.


Looking good.:encouragement:

Thanks. Working in the heat is one thing but the heat and the sun just sucks all the energy out of me. Weather is a bit better today, still humid but not quite as hot and the wind is blowing.

Good news is the boat is basically ready to hit the water. Still need to pull one drive just to replace the gasket, but otherwise it is ready. Only real items left on the list are:

In line fuse holder between the auto bilge pump and battery. I have the manual function wired to a switch on the dash.

Bulb for the stern light. It is a dual bulb light. One is the anchor light and one is the running light. The running light is out.

Fuses. Blew the lights fuse when I was messing with the burned out stern light.

Horn. Power to the horn but it does not work.

And the hardest thing I have left, find a replacement top for the stern light. I lost it through out the build process. It is going to be a chore to find an original 1973 stern light cover. Checked E-bay and there is not much to be found for stern light lenses, let alone ones from a Sea Ray.

Still lots of work left, but at least the boat will be usable.

 

[sheboyganjohn]

Getting slightly ahead of my self, but I have a question. I bought un-backed vinyl since I am using it for the interior cushions, but I also plan on using it for the side panels. What type of backing material do you suggest for the side panels? From the looking I have done I keep finding really expensive foam. I know there are other backings I can use, just don't know what will work properly. Also looking for something to use as a glue in application between the vinyl on the side shelves and up the side of the boat.

 

[sheboyganjohn]

The project that never quits giving... headaches. Got the second out drive on and went to adjust shift cables. The second out drive adjusted up just fine, following the book. Went to the first drive I put on and forward/ neutral were just fine, could not get it to lock in reverse. I pulled the lower cable off the shift bracket, and even pulling it by hand, could not get it to lock in reverse. The best I could get was to get it to stop where you had to put a good amount of weight on the prop, but it would still slip. Looks like I may need to pull the drive again and see what is going on. I thought it was locking in reverse fine off the boat, but I resealed them so long ago that I don't recall.

 

[sheboyganjohn]

Good news is there is nothing wrong with the drive. I was able to reach into the back side of the drive an push/turn the shift shaft just a minute amount and the prop locked in reverse. So it looks like a new shift cable for the port engine is in order. The new issue, because something else always has to pop up, is I cannot get fuel to the engine from the fuel tank. Well I can get fuel, but once I get the engine started it cannot keep up and dies. I have been using a fuel bulb to pump fuel up to the carb. I then pull the bulb out of line and hook the fuel line back up to the fuel pump. Engine will start but sucks all the fuel out of the carb then dies. Engine ran fine a week or so ago on a portable tank. Fuel pump is brand new and the carb was a fresh rebuild. Then again it was at the end of the day yesterday and I had to get ready to go out to dinner then the Venetian boat parade so maybe everything will finally work today. Worst case I will put a fuel bulb in line with each engine.

Off to the boat. Wish me luck.

 

[sheboyganjohn]

Found the problem. My brand new fuel pump went out. Take a look, this is how it came off the motor. No idea how it came off that way, the arm would have been under the cam instead of riding against it. I ran it for 25 minutes for the cam break in and had no issue. The arm on the fuel pump is stuck in that position. Good thing I saved the old fuel pump. It still worked, just figured I would replace it on the new motor. Well at least I have a running boat now.

 

[sheboyganjohn]

Freaking heat and humidity are back. I am just going to finish up what I can today and button everything up. We are going camping on a lake through the weekend starting tomorrow. I am going to take the boat with us and do the first launch there. I will post up how it goes.