19' CC Rebuild/Refresh

SBTOM

Petty Officer 1st Class
Joined
Jul 22, 2009
Messages
275
I bought this 19' trophy center console a few months back in pretty good condition. It has an oil injected 100 HP merc on it. The wiring was all completely shot and it needed a few tweaks here and there to get it out in the ocean, but it is finally to the point where I can take it out for a day of fishing without being too worried about actually making it back to the harbor. Now that I have spent some time on it, there are a few key changes that I want to make, and I figure that as long as I am going to be taking the outboard off, etc. I might as well check to make sure everything is in tact and well maintained. (denial stage 1 ?) This first photo is the boat as it existed a few weeks ago:

CC%20Rebuild


Unfortunately, as you can see in that photo, the boat doesn't fit in my driveway. So, after a few parking tickets for having it hanging over the sidewalk, I decided to start storing it on the back lot at my family's factory. I forgot to cover it up last time I went out of town and one of the guys out in the shop accidentally dumped a bunch of steel wool shavings on it while trying to empty a drum into the dumpster that it is parked next to. It was raining so the steel wool rusted, and now the gelcoat is all stained. It was kind of oxidized and cracked in a few places so I plan on re-doing it. I guess its not too big of a deal, but after I get it sanded down and re-coated, I think I will remember to keep it covered!

CC%20Rebuild


http://s741.photobucket.com/albums/xx59/Radnar3/CC Rebuild/?action=view&current=frontrust.jpg

CC%20Rebuild


I'm really looking forward to this project, and I'm glad to have all of you iboaters here for some advice! (I'm going to need a lot)

Things I plan on doing

1.) Pull engine, check transom (again)

2.) Check stringers with cap on, if bad remove cap

3.) Modify transom so that I can have a shallower splash well and a higher back

4.) Check tank, new fuel sending unit

5.) new dash

6.) Sand and fair EVERYTHING. I might respray the gel coat or I might go with paint... not sure yet.

7.) New lights

8.) replace all wood trim

9.) pump out for bait tank, and salt water wash down

10.) If I can afford a kicker motor, that would be awesome, but we'll see.

Thanks in advance for all of the help! - Tom
 

ezmobee

Supreme Mariner
Joined
Mar 26, 2007
Messages
23,767
Re: 19' CC Rebuild/Refresh

Nice boat. Definitely worth it to fix it up. That's quite the unique (sucky) situation with the steel wool. What a mess!
 

boatflipper

Chief Petty Officer
Joined
Jun 16, 2009
Messages
500
Re: 19' CC Rebuild/Refresh

Sunds like you have good plans for her!!
On my computer, the pitures you posted aren't coming through...maybe it's just my computer but you may want to look into it...
Good Luck!!
 

SBTOM

Petty Officer 1st Class
Joined
Jul 22, 2009
Messages
275
Re: 19' CC Rebuild/Refresh

Thanks for the heads up! Let me try again, because I think that I might have accidentally put the email link instead of the direct link.

overallshot.jpg


frontrust.jpg


fronthold.jpg


backrust.jpg
 

ondarvr

Supreme Mariner
Joined
Apr 6, 2005
Messages
11,527
Re: 19' CC Rebuild/Refresh

Get a cleaner with oxalic acid in it, it should remove the rust stains and leave a nice clean surface.
 

SBTOM

Petty Officer 1st Class
Joined
Jul 22, 2009
Messages
275
Re: 19' CC Rebuild/Refresh

Thanks for the tip! I did a quick search and found out that they sell straight-up oxalic acid at west marine so I could pick that up on my way home... is there any risk to using that? Is there a brand that you would recommend? Also, do I have to worry about that eating away at other things if it runs off of the actual surface of the gel coat a bit?

I'm going to spend some time just doing general clean up and disassembly this afternoon so that I can move the boat inside for weekend and pull the motor. I'll post some pics of the tear-down later on tonight or tomorrow... My fingers are crossed that I don't find any really bad news!
 

noworries79

Petty Officer 2nd Class
Joined
Aug 27, 2008
Messages
171
Re: 19' CC Rebuild/Refresh

Sweet looking boat! It definitely has potential, good luck!
 

ondarvr

Supreme Mariner
Joined
Apr 6, 2005
Messages
11,527
Re: 19' CC Rebuild/Refresh

I think it will attack some types of metal, but not SS, it should say on the container.
 

SBTOM

Petty Officer 1st Class
Joined
Jul 22, 2009
Messages
275
Re: 19' CC Rebuild/Refresh

Thanks, I'll check it out on my way home.

I spent a little time this afternoon and got some stuff done. Here is a before picture of the dash... Its functional as is, but the material that the gauges are mounted seems like some kind of marine grade gator board and I want to go with something a little stiffer.... might glass it in flush. There are some electronics missing, but you get the idea....

dashbefore.jpg


I started by pulling most of the hardware off of the rails and bow. There are a few things that I don't want to remove until I know how they are anchored (the back cleats, and the guide for the anchor roller- not sure what that is actually called.) I did manage to remove the tower and drill out most of the rivets for the rub rail. The process of removing the tower may or may not have inspired me to fab up a new one out of aluminum. This first photo shows the boat partially stripped down and the second shows me weighing it out on a pallet scale:

notower.jpg


weighingtower.jpg


There are two problems with it as-is. It is starting to rust a bit, and it is also super heavy. 80+ pounds. I'm going to work up a SolidWorks model tonight and see what the savings would be in Aluminum. If I end up keeping the current tower, I think I might try and Zinc plate it and then powder coat it. Does anyone have any thoughts on that one? If I do aluminum, do I have to clear-coat it or can I just polish it?

This last photo shows the boat in its current state... it looks like a wreck! I guess I am committed at this point!

electronicsanddeckhardwareremoved.jpg
 

jspano

Senior Chief Petty Officer
Joined
Oct 30, 2009
Messages
790
Re: 19' CC Rebuild/Refresh

if there is a john deere landscapes(lesco) near you look for rust-eraser. 1 gal liq. just don't get it on metal or glass. it will etch/ clean alum too.
 

SBTOM

Petty Officer 1st Class
Joined
Jul 22, 2009
Messages
275
Re: 19' CC Rebuild/Refresh

Well its about to start raining here and I don't have the boat cleaned up enough that I can move it inside for the weekend so I am going to have to chip away at some smaller projects. I am aiming for about a month and a half time-frame for this whole project so I need to have the all of the glass work done in the next two weeks. The good news is that it seems as though the cap was removed within the last couple of years (rivets had been drilled out previously so there were two sets of holes) so I have my fingers crossed that the PO might have sealed things up a bit. Guess I won't know until I pull the cap.

I did manage to put together some quick SolidWorks models to help me decide what to do about the tower. I decided that I want to have a detachable sun shade on the top so I am looking for ways to build that... I didn't take the time to match it exactly to what I have now, but I threw a couple of screen shots in here:

http://i741.photobucket.com/albums/xx59/Radnar3/CC Rebuild/tower1.jpg

http://i741.photobucket.com/albums/xx59/Radnar3/CC Rebuild/towerwithcover.jpg

If I build it in 6061, It will weigh about 40 pounds as shown. I'm still not sure whether I want to just refurbish the existing tower though... I guess its one of those "if it ain't broke... " type of things. Guess I'll do a couple test patches with a belt file and see how bad the rust is. Either way, I am going to want to build a hard top... anyone have any ideas on how to go about that?

also, I'm picking up all of the vinyl to redo the upholstery and make up some new cushions for jump seats after work... Does anyone know whether I need to buy "marine-grade" zippers or can I just use regular ones?

Thanks! - Tom
 
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SBTOM

Petty Officer 1st Class
Joined
Jul 22, 2009
Messages
275
Re: 19' CC Rebuild/Refresh

Used boats always seem to have a lot of secrets... in the case of this one, they aren't all bad! 90% of the wood I have seen in taking it apart has been in good condition, and I haven't seen a lot of de-lam on the glass so I'm pretty pumped. I have no way of telling the condition of the front of the stringers until I take the cap off, but I did notice everything that I can see from the transom forward about 3.5 feet seems to be fully glassed. Pretty sure the PO did a re-build at some point about 10 years ago.

Progress report: Yesterday I pulled the engine (cheated and used a forklift and some tow straps.) Heres a quick photo from just after:

2-20-status.jpg


Don't worry about the pipe wrench, I promise I was actually using it on pipes!

These last two photos are from today. I got the deck stripped down... removed all the plates, the griptape, tackleboxes, baitwell, etc. My goal is to dive into the itchy part by mid week.

2-21-status.jpg


2-21-status2.jpg


Hope everyone had a good weekend, this guy is gonna go find a cold beer! Cheers- Tom
 

SBTOM

Petty Officer 1st Class
Joined
Jul 22, 2009
Messages
275
Re: 19' CC Rebuild/Refresh

I'm wondering whether anyone has recommendations of a good source for marine grade vinyl, or if there are any other materials that would be better. Thanks! - tom
 

SBTOM

Petty Officer 1st Class
Joined
Jul 22, 2009
Messages
275
Re: 19' CC Rebuild/Refresh

This would be to re-skin the seats as well as make some new ones... I think the floor will be textured gel coat. Vinyl would be my top choice at the moment, but I'm open to any suggestions...
 

ezmobee

Supreme Mariner
Joined
Mar 26, 2007
Messages
23,767
Re: 19' CC Rebuild/Refresh

Well than I have heard you can get marein vinyl at JoAnn Fabrics and use one of their crazy coupons on it.
 

SBTOM

Petty Officer 1st Class
Joined
Jul 22, 2009
Messages
275
Re: 19' CC Rebuild/Refresh

I haven't posted updates because I have been sort of plugging away at small parts of this project. I'm definitely going to need some advice on this next step though! First, the good news... I got crazy with with a forstner bit and the shavings came out dry:

drywoodshavings.jpg


now if only I didn't have a bunch of holes in my boat! :D

Now the bad news, and this is the part that I need help with. The flange that connects the hull to the cap is shot. parts of it are ok, but I am definitely going to have to re-glass the whole thing. Here are a few pics:

transomcapdamage.jpg


capflange.jpg


Anyone have any cool tricks for this? Here are a couple of things that I came up with:

1.) Feather the existing flange out with a grinder

2.) wax up a bunch of roof flashing flashing, and slip it in between the cap and the hull so that I have a surface to lay the new flange up on

3.) Body filler on existing holes

4.) 2 layers of 3/4 oz biaxial

3.) Body work, spot prime, and then gel coat when I do the rest of the boat

If there was a company that offered strips of nice, smooth fiberglass that I could just graft on there, it would save me a TON of time. Anyone have any good ideas? Thanks - Tom
 

SBTOM

Petty Officer 1st Class
Joined
Jul 22, 2009
Messages
275
Re: 19' CC Rebuild/Refresh

I've been going back and forth for a while about whether I want to build a gill bracket for the back of this thing. I think I' decided not to do it, so I've started re-working the transom and building a new splash well. I cut out the existing one on Monday and was stoked to find out that the wood is nice and dry/solid. there is one section of the transom plywood that I will have to repair before I continue though. Maybe I could just pour some sea-cast in there?

Don't worry, I didn't cut the whole thing apart with the dozuki saw!

Dozukisaw.jpg


This is the flaw in the transom... starts out about 3/16" wide and tapers down about 2 inches.

Transomflaw.jpg


Also, when I cut out the splashwell, I found a whole pump that I never knew was there! I'm really hoping that it is for a washdown system, but realistically, I have no idea what it is... Anyone have any ideas?

Here is the pump:

Mysterypump.jpg


and here is the nozzle that one end of it is connected to:

Mysteryvalve.jpg


Thanks - Tom
 

jspano

Senior Chief Petty Officer
Joined
Oct 30, 2009
Messages
790
Re: 19' CC Rebuild/Refresh

looks like a saltwater wash down. we use to install them to rinse off any big messes right away. we also had a fresh water one but of course it was limited, but wash good the rinse off after a dip
 
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