1969 Sea Ray Rebuild (and mods) [SPLASHED Sept 2017]

proshadetree

Lieutenant Commander
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Jul 19, 2008
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1,887
That blue looks great beside that outdrive. Getting warmer test drive in a he near future? Awesome work man.
 

CrazyFinn

Petty Officer 1st Class
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Dec 12, 2016
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Had to work on the weekend, so didn't get a lot done, but I did manage to fabricate a new interior side panel to attach the throttle/shift lever. Sealed it all up with glass last night, still need to paint it before it gets installed. Then I can run the cables to get ready for the engine to go in...

Still lots to do before it leaves the garage: Need to seal up all of the seat boxes with glass, sand, paint the interior. Build a new engine cover. Make new seat cushions. Install flooring. Install new seals in the upper part of the drive. Gonna be a while before it's ready for the water, but it will happen in the next month or so (I hope). I can see the light at the end of the tunnel!

And maybe I'm nuts, but I'm already browsing Kijiji for my next project...
 

CrazyFinn

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Dec 12, 2016
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A bit more progress the past few days.

Shift/throttle lever (complete with a new throttle only button) is installed, cables routed. New lower shift cable installed. Engine compartment is ready to have the engine go in.

Got the seat boxes glassed in and sealed up.

That was Thursday/Friday last week. Got them sanded and primed yesterday.

Went out on Saturday with my wife and bought the vinyl for the new seat cushions, and also cut the foam for the seats so she can start on her portion of the boat rebuild (sewing the seat cushions).

Dug the engine out of the corner of the garage where it has been sitting since I pulled it out of the boat, hung it on the hoist, and hauled it out into the middle of the driveway. Set it on blocks to clean it, check wiring (it's a mess), and see if I could get the thing going. No point installing it in the boat if it doesn't start!

So... I got it cleaned up somewhat, installed all of the water drain plugs, checked the oil (it's clean), rigged up a temporary gravity feed fuel supply from the hoist, got the necessary wiring connected to a battery to see what happens.

So - the good: no water leaks anywhere. Water comes out of the exhaust like it's supposed to, and nowhere else. The starter cranks fine, engine turns over well.

The not so good: It doesn't fire. Checked the plugs, no spark. Fuel is getting to the cylinders. Plugs look fine. Pulled out my ancient tach/dwell meter (I kept it around as my dad's Jeep still has a points type ignition). Nothing from the points/distributor. Coil looks new, but I'm thinking of just ordering a complete Pertronix ignitor and coil combo. Need to clean the points, check the condenser, but ran out of time yesterday.

Getting closer...
 
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archbuilder

Vice Admiral
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Sep 12, 2009
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5,697
You are moving along nicely! I vote for Pertronix, it doesn't cost that much and solves a lot of headaches!
 

Patfromny

Lieutenant Junior Grade
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Dec 2, 2012
Messages
1,197
Check to see if the pertronics uses 12 volt power. An old points system used something like 8 volts so you may need to run a new power wire. Not sure if boats were the same as cars in that respect.
 

mickyryan

Rear Admiral
Joined
Apr 18, 2016
Messages
4,216
you would just need to cut the resister wire out to get the full 12 v if it even still has it
 

CrazyFinn

Petty Officer 1st Class
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Dec 12, 2016
Messages
357
you would just need to cut the resister wire out to get the full 12 v if it even still has it


It currently has a couple of ballast resistors in series. Since it's getting all new wiring when I drop the motor in the boat, not a problem.
 

CrazyFinn

Petty Officer 1st Class
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Dec 12, 2016
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357
I didn't get anything done on the boat yesterday, even though I had the day off. I did go to the local marina to order some new bushings and seals for the shift shaft. My daughter decided that she was going to re-paint the kitchen as a gift to my wife for mothers day - so ended up helping her get started with that - she's done University for the year, and hasn't found a summer job yet and was getting bored...

Still - progress was made as my dad dragged out the gearcase and welded/re-built the broken and bent skeg on the bottom. A bit of paint and it will be looking good!

Oh - and I also went and looked at another project boat I found on Kijiji. I'll keep looking. Looking for a 24' to 26' cruiser to re-build.
 

CrazyFinn

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Dec 12, 2016
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357
My project is getting there, the end is in sight (although still a little ways off). Waiting for a few engine/drive parts so I can install it all, then need to build an engine lid and finish up a few things on the interior.

So what did I do?

I went out for a drive with my wife today and ended up buying another boat. A very rotten old SRV240 Weekender with a seemingly good Mercruiser/Ford engine and a solid trailer. Mechanically complete, but the interior is shot. Transom is soft, stringers need to be replaced, floor is a mess. It was cheap. Picking it up next weekend.

This is gonna be fun!

Yup, I think I'm officially crazy...
 

CrazyFinn

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Dec 12, 2016
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357
Wednesday last week, started getting ready to put the motor back in the boat - didn't get far before I discovered that the inside of the exhaust riser is rotted out (discovered some water in the cylinders that wasn't there the last time I was trying to start the motor).

So... I pulled the manifold, head, oil pan. Wanted to give it a more thorough inspection. It all looks good inside, considering the age. New gasket set and exhaust riser ordered, waiting for them to show up.

Got nothing done on the boat this holiday weekend - went fishing with my dad in his canoe Saturday (got a couple of pike), picked up my next project on Sunday, and went to help my father-in-law figure out some steering issues on his boat (Charger 18DL with a Merc 225 ProMax on it).
 
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CrazyFinn

Petty Officer 1st Class
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Dec 12, 2016
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357
Quick update - the motor is mostly back together. Head, oil pan, valve cover all back on. New Pertronix ignitor and coil installed. Manifold and new exhaust riser will go on next, and then it needs to go back in the boat. Been slow progress the past couple of weeks. Week of vacation followed by a family funeral in another city...
 

CrazyFinn

Petty Officer 1st Class
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Dec 12, 2016
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357
Quick update - the engine is finally fully assembled, ready to go back in the boat, and (as of 30 minutes ago), the engine runs! Fired it up sitting on blocks in the driveway. It's a beautiful sound...
 

Freedom245

Recruit
Joined
Jun 30, 2017
Messages
2
Just joined forum... and enjoyed reading about your project. Loved the creativity. You are encouraging me to post my custom bowsprit project for my boat.
 

CrazyFinn

Petty Officer 1st Class
Joined
Dec 12, 2016
Messages
357
Just joined forum... and enjoyed reading about your project. Loved the creativity. You are encouraging me to post my custom bowsprit project for my boat.


Glad you enjoyed it!

Got the motor back in the boat on Sunday, engine mounts installed, alignment all done (will check it again before the drive goes on). Electrical, fuel line, cooling hoses all connected. Decided to order a new alternator for it as I realized that I had no regulator for the original alternator, and no idea if it even works!

Now I have to start working on creating the lid for the engine compartment.
 

CrazyFinn

Petty Officer 1st Class
Joined
Dec 12, 2016
Messages
357
A little more progress the past couple of evenings...

Got the side vents/hoses/bilge blower hose all installed, blower works fine. Thru hull fittings and bilge pumps are connected.

Connected the battery last night - turned the key and the engine fired instantly (with the gas left in the float bowl from my engine test last week - before I installed it in the boat). Only let it run for a couple of seconds - no outdrive, or water pump belt installed. Did run long enough to show me that the original Mercruiser tach still works. At least it registers something - will have to determine accuracy later!
 

CrazyFinn

Petty Officer 1st Class
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Dec 12, 2016
Messages
357
Some progress on the engine lid... Made a frame out of 3/4" plywood.

lid_frame.JPG

Fitted a top layer using 3/8" plywood.

lid_plywood.JPG

Next step is to cover the plywood with glass, and then paint to match the rest of the boat. The door will have stainless hinges surface mounted on the near side, two round stainless latches on the far side, hydraulic lift assist to keep it from falling on my head when open.

New alternator showed up, need to get that installed once I'm done with the engine lid. Then a bit more interior work (switch panel, seat cushions, etc.), new seals in outdrive and install, and hopefully I have a functional boat!
 
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