16' Sunray Rehab

[Pun]

Hello all. I've recently taken on my first rehab project. I don't have the paperwork on it yet, but what I believe I have is a 1985 Sunray bowrider. It's in need of a deck replacement and a new upholstery job. The 75hp Merc outboard is in pristine condition, and besides a few dock scars, the outside of the hull and gelcoat are in great shape. I dont think the bottom of the plywood was treated in any way by the manufacturer, thus the floor is rotten. I've got most of the floor out and it seems like the stringers are in beautiful shape, luckily, They're totally encased in glass and seem solid as a rock. I'll try to get some pictures up soon.<br /><br />A couple questions.<br /><br />I've heard a grinder with a cutoff wheel is the best way to deal with the edges where the hull meets the deck. Once I get that cut made, there will be a bit of deck leftover since I dont want to risk making the cut too close to the hull. How do I remove that?<br /><br />When I get the new deck down, I'm sure there will be a small gap between the deck edge and the hull. Does that have to be filled in with anything?<br /><br />What is the best way to remove the old carpet glue and foam that is attached to the hull? <br /><br />Do I have tp prep the old hull glass in any way to promote adhesion of the glass tape I'll use to attach the new deck to the old hull?<br /><br />Hope that wasn't too much to ask at one time. Thanks in advance! <br /><br />Vince from Chicago

 

[headgardener]

Re: 16' Sunray Rehab

Hi Pun,<br />I have also just started, within the last week a renovation project on what I think is a 1989/90 Searay 190 closed bow or cuddy cabin, in a very sorry condition. I am based in Menorca part of the Balearic Islands in the Meditteranean. I have already had some excellent help on these forums especially in the identification of the installed engine. I would really like to keep in touch with your project as I think exchanges of our progress could help us both. Do you have any Pictures ?.<br />My email address if you are interested in striking up a conversation is headgardener@terra.es.<br />Regards Geoff

 

[Realgun]

Re: 16' Sunray Rehab

Well the way it works on my Bayliner is they glassed the crap outa the top of the deck where the floor meets the hull. The easy way is to cut as close as you can but not into the hull. Once you cut the glass or grind away the fiberglass on top of the floor, which is what I do, you will see the hull and the end of the wood. I actually just pry the wood away from the hull with a crowbar. It seems the chopper glass does not stick well to the wood. Then I just use a grinding wheel to get rid of the excess glass.<br /><br />Use care and you will have it out in no time!

 

[JasonJ]

Re: 16' Sunray Rehab

Use a grinding wheel to remove excess glass, and use that same grinding wheel to rough up the surfaces you plan to glass to. Clean very thoroughly with acetone right before you begin. Good luck...

 

[Pun]

Re: 16' Sunray Rehab

Thanks for the advice fellas. Here are some pictures of the project.<br /><br />Here she is with 8 years of dirt washed off of her and the ugly, faded brown pinstriping removed. I believe she has potential.<br />

<br /><br />The fore section with the floor cut out. Stringers are hard as a rock inside! Phew!<br />

<br /><br />The aft section with the floor out. I'm not sure what to do with that well back there that holds the tank. I'm thinking about just leaving it. The board underneath has some rot, but I think I'll try to rig it somehow. <br />

<br /><br />Here's a shot of the near mint condition 1985 Merc 75.<br />

<br /><br />I'm going to use 1/2" marine grade ply and epoxy resin to rebuild the deck. What kind of cloth, matting, tape do I need? I'm not sure what I need. Any suggestions. Also, what's the best way to cut that curved shape? The old floor was trashed and came out in pieces, so I can't use it for a template. Thanks in advance!<br /><br />Gardener, good luck with yours, man. My AIM nick is Luc4Br4zz1 if you'd like to chat. Or you can get my almost any time in IRC chat. irc.gamesurge.org, channel is #Descent3

 

[Chris1956]

Re: 16' Sunray Rehab

Pun, After you install the new plywood floor (you are going to screw it to the stringers, right?, use ss screws), fill the gap between the floor and hull with polyester putty. After the putty hardens, use several layers(4+) of saturated glass cloth and mat to reinforce the joint. Also lay at least two layers of saturated cloth over the entire floor. I think you can use poly resin for this part of the restoration, it is plenty strong enough.

 

[Pun]

Re: 16' Sunray Rehab

I keep hearing that epoxy is so much better than the polyester. I dont mind spending the extra cash if it's gonnna be a better build. Opinions?<br /><br />Also, where do you all buy your resins, matting, cloth, tape, etc?

 

[quantumleap]

Re: 16' Sunray Rehab

Try a 3M sanding wheel that fits on your angle grinder to smooth the edges. It takes the built up glass off quicker but without the risk of cutting into the hull.

 

[JasonJ]

Re: 16' Sunray Rehab

If you are willing to spend the loot, go epoxy, just remember that you cannot bond polyester to epoxy, but you can bond epoxy to polyester. You'll just have to use epoxy on epoxy from here on out. When I layed my floor, I used resin soaked strips layed on top of the stringers, and screwed the floor down using stainless screws every 6 inches. I used one layer of heavy mat to sheath the floor in, and a one foot strip of heavy roving around the entire perimeter of the floor where it joined the sides and transom, and even with poly, it has proven more than strong enough. It is not uncommon for me to accidently catch air or pound through the rough and everything is very solid. <br /><br />That Merc looks pretty darn good (but I am horribly biased towards Merc anyway, so what do I know).

 

[Winger Ed.]

Re: 16' Sunray Rehab

I've seen it done where a fella made cardboard templates for the weird angles on his floor. Once he got them right, patterned them onto the plywood.<br /><br />If you are careful, you might could save the little edge of glass left from the edge of the old floor. Being basically a triangle, you could slide the new wood forward & under the edge of the old glass that sealed the deck to the sides.<br /><br />Mop it down with resin before you slide it in, lay another strip along there to bond the old glass to the new wood, and you'd have a good repair with the new floor set in exactly the right place in relation to the height of the stringers it will have to cover. <br /><br />That outside edge of the floor and the way the floor screws down to the stringers is where you get most of the hull's strength to resist a twist, so it has to be a solid attaachment of the two.

 

[Pun]

Re: 16' Sunray Rehab

Yeah, Jason, the motor is sweet. I pulled the covers off and there wasnt even any dust in there. All wiring is nice and soft and brand new looking. I did pull the buttom end and rebuild the water pump. But other than that the motor needed nothing but plugs. she fired up on the first try.<br /><br />Winger, is that guy still around? I'm wondering how he cut the cardboard template perfectly...

 

[Pun]

Re: 16' Sunray Rehab

Sorry for the old thread resurrection, but I figured I'd keep this thread as a place to post advancements in the rebuild.<br /><br />Here are some pics of the latest progress!<br /><br />1/2" Marine Grade all sealed with two coats and ready to go!<br />

<br /><br />

<br /><br />I know a lot of people say to experiment around on scrap pieces of wood before attempting to do fiberglass work. I decided to "experiment" with my ski well floor. I figured if I screwed it up, it wouldnt be that big of a deal. Did the tabbing in on Sunday morning, got to work this morning and MAN it looked good. It's amazing the strength of this stuff! Anyway, here's a pic of the 1/4" exterior grade plywood all tabbed in. Note the knotholes filled with epoxy/wood flour "peanut butter".<br />

<br /><br />The board was a little warped so I used that big brick to hold it flat while the epoxy dried. Sorry Realgun, I didnt have any ROCKS.

 

[JasonJ]

Re: 16' Sunray Rehab

Looks good so far, can't wait to see the finished product.

 

[AMD Rules]

Re: 16' Sunray Rehab

Hey Pun,<br /> <br />I'm trying to collect info on Sunray boats....so far come up basically empty.<br /> <br />Check out this site.... though basically inactive. 1980's sunray power boats owners<br /> <br />Let me know if you have any information about where they were made, or any literature etc.... I don't think they have anything to do with the current Fiesta/Sunray pontoon boats out of the USA. As far as I know Sunrays up to the early 90's were made in Quebec Canada somewhere. My boat for sure says made in Quebec Canada. Since out of business.<br /> <br />Your boat restoration looks great so far. Thumbs-up!

 

[tengals123]

Re: 16' Sunray Rehab

yeah, PUN that's a nice looking boat. I look forward to seeing it done!<br />cheers

 

[Pun]

Re: 16' Sunray Rehab

Thanks, fellas. <br /><br />AMD - My Sunray says Paxton, IL. It was bought new in Dowagiac Michigan in or around 1985. That's all I know so far.<br /><br />More pix tomorrow!

 

[Pun]

Re: 16' Sunray Rehab

my boat has a deck!<br /><br />

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<br /><br />carpeted the ski well before I put the floor down.<br /><br />38 stainless steel screws in that bad boy. I sanded and buttered the stringers with epoxy mixed with wood flour before screwing it down. Tomorrow I'll start the fillet joint and by early next week, I should have it taped and glassed in.<br /><br />If I could only remember where I left that hammer...

 

[Pun]

Re: 16' Sunray Rehab

Did the fillet joint today. Well, most of it anyway. Ran out of filler. Pics tomorrow.

 

[Realgun]

Re: 16' Sunray Rehab

Hey Mark42 you see that gravity focusing mass in the boat in the second picture? I think my Idea is catching on. Nice Job Pun!!!! <br /><br /><br />Thats a rock for the scientifically impaired

 

[Pun]

Re: 16' Sunray Rehab

Small update:<br /><br />Fillet joint ready for sanding. I used epoxy resin and wood flour to make the joint. Made the joint in two steps. First I filled the crack flush with the deck surface. Then I sanded smooth and applied another coat to make the joint stronger and also to make a smoother transition from floor to hull. <br /><br />

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