1986 Capri 1600 O/B Remodel Project

[dorelse]

Ok...here's been my project over the last year. I pulled most of the postings from another site, but iboats was integral to my success on this project as well, so I wanted to document my build here as well. I hope you enjoy the pictures!

I thought I would start a new thread documenting all my progress on my 1986 "Boat Magazine's" "Boat of the Year" remodel. (Sorry, but that's a running joke in my family.)

I purchased this boat for $750.00 mostly b/c the motor is in really good condition, 135 lbs compression across all 3 cylinders, and because it was cheap!

The yellow tub pictured sat below the boat catching water for 3 weeks after I put it in my garage. It was soaked through & through.

I towed the boat home, drain plug out, for 15 miles, and STILL drained 13 gallons of water out of the boat. It wasn't good. However, that said, the floor of the boat is solid. (A testament to a quality build by Bayliner.)

My goal with this boat is not to spend more than $750 fixing it up. Which means I need to use a lot of wood from my scrap pile, and get creative wherever, whenever possible. My total is up to around $500 so far...but I think I have the majority of the materials purchased.

Notice the plywood piece on the floor? I found that floating in the ski locker area...its for added floor support.

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

Water running out from the foam & all the wood rot:

Rear Flotation Box:

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

Pulled up the wafer thin carpet.

Cleaned out the bow flotation boxes:

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

Proof that an OEM outboard Tach exists, and I've got one!

Dash fully laid out. (Not wired up yet though.)

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

I took a Wise back-to-back seat and broke it down into its 4 individual pieces. The plan is to turn them into 2 captains chairs that are locked into place. Later pictures will show what I've done.

The rear bench:

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

Again, keeping with the reuse as much as possible theme. The hinges were on the seats from Wise. I took them off, used my dremel tool to cut notches in the hinges and attach them to the seat and to the seat base already in the boat.

A close up view:

And the starboard side:

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

The back 1/2 of the seats will be lopped off. The final design will be 2 captains, a rear bench and a small but functional sundeck for my wife to lay out on.

A good picture of the open seat bottom:

The reason for the overkill on the seat backs is 1) Needs to be strong! 2) I wanted a butt perch, b/c I have a habit of sitting on the top of the seat. The Wise seat back will mount to this, and then I have fabric to upholster the rest of this to match.

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

I think the telltale will be welcome piece of mind when using my boat. Here's mine:


Before:

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

I wanted a factory look, so I used a brass fitting and painted it white to match.

The finished product:

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

Rotted wood in the bow:

This pictures speak volumes about how nice the upholstery used to be. The non-faded section was tucked under the bow gelcoat, and never saw sunlight. Too bad...

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

A few more:

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

Just a couple picts. I'm getting ready to build out the rear bench base, and was just testing heights.

The general idea is a smaller bench seat that allows for passage on either side so that wet people don't have to climb over the seats to get in and out. There should be foot steps on either side of the seat.

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

Widened and moved forward my ski locker. I'm hopeful this will allow my kneeboard to fit under the floor. It also solved an issue I had as the floor was cracked at a huge knot about 5 inches 'North' of the front of the old ski locker.

Also sanded down the floor pretty good as well. The plan is to make the new 'bottom' of the ski door, and add a little 'stringer' to provide some support back there as well.

I'm going to leave a smaller access door (about 12"x12") for access under the bench I'll be adding next week.

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

I'm kinda liking the forced vacation time away from work. (We were all req'd to lower our vacation banks to get it off the company books as a liability. I have to get down from 12 weeks banked to about 8 weeks, before May.)

Lots of time off to work on the boat. Anyway, here's more progress. I have 2 more of each to cut out yet, as I want more width and strength then I have today, but, the rough stuff is done.

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

A couple more.

The rear bench will cover up most of the patched floor. I still wanted an access to the very back drain area, just in case, so that access hole will be inside the bench base.

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

Started sealing all the wood in resin.

So many little pieces...

Believe it or not, this is the bench seat base, its all sealed together now, and I will be cutting some holes in it to lighten it up. It wil be covered in carpet, so the little indentations won't matter.

The new port side seat back support installed. The holed out piece is support for the outside fiberglass 'box', and also to support that side of the seat back. Its all glued/sealed together with resin...and it isn't coming out. The holes will improve ventilation, and lightened it up a bit. It'll be covered with carpet eventually.

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

Starboard side seat back...installed and in place with its support piece as well.

I took off the transom drain plug, as it never looked like it was sealing very well. Thats when I discovered a poor patch job on the transom. I don't believe it let any water in, but it was this blue stuff I'd never seen before.

I'm going to patch it up right with some gelcoat when I get to it. Looks like the outboard somehow slammed down into the transom...as the lower unit has a perfect paint chip on it and lines up perfectly.

 

[dorelse]

Re: 1986 Capri 1600 O/B Remodel Project

My 'stringers' such that they are...3 coats of resin...they aren't moving. I am debating on adding 2 lower horizontal braces, just to be sure, but they're glued down good.