1990 Gemini 200DCX

BADPONCHO

Cadet
Joined
Aug 8, 2010
Messages
17
Hey everybody! We are in the process of beginning a restoration on our 1990 Gemini 200DCX, my father bought the boat new in 1990 but was parked in 1995 until now.

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eclark53520

Petty Officer 2nd Class
Joined
Sep 2, 2010
Messages
174
Re: 1990 Gemini 200DCX

Ouch, brand new boat parked in the weather after 5 years of use?

That's rough. Looks like it's going to need a full on restore! Good luck!
 

BADPONCHO

Cadet
Joined
Aug 8, 2010
Messages
17
Re: 1990 Gemini 200DCX

So at the end of day one we had the front deck stripped down to the old glue.


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BADPONCHO

Cadet
Joined
Aug 8, 2010
Messages
17
Re: 1990 Gemini 200DCX

Day two progress!

Day two of the restoration we stripped the carpet from the floor and the rear deck, with the carper completely stripped from the hull it is just about time to start sanding the old glue off and think about the new carpet. I apologize for no pictures today, did the video though. Hope you enjoy!

 

Woodonglass

Supreme Mariner
Joined
Dec 29, 2009
Messages
25,929
Re: 1990 Gemini 200DCX

Have you given any thought to the fact that a 22 year old boat, sitting out in the elements for the past 17 years might have some rot issues in the stringers and transom? Are there any soft spots in the deck, especially the lower deck? Have you really push HARD up and down on the lower leg of the motor to see if there is any flex in the transom? There shold be None! Is there any cracking or or checking in the gelcoat where the motor mounts to the transom? Have you at least done a "Tap Test" with a hammer to see if you can tell any difference in the Sound when you tap on the transom? I am being a pest, because I would hate to see you do all this work on the deck to make her "All Purdy" and then have to rip it all out and fix rot below the deck. 20 year old boats seem to always have these issues that I have described. You might be one of the lucky ones like I was. Most aren't.
 

BADPONCHO

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Joined
Aug 8, 2010
Messages
17
Re: 1990 Gemini 200DCX

Actually the boat structural stuff looks incredible, honestly I was rather surprised. While I have the deck open I actually planned on taking out a few pieces of the flooring to check on that kind of stuff.

No worries! Appreciate the thought!
 

Woodonglass

Supreme Mariner
Joined
Dec 29, 2009
Messages
25,929
Re: 1990 Gemini 200DCX

Looks can be deceiving. Have you tested the transom??? If/When you remove some decking you need to "Core sample" the stringers to ensure they are good and if you can get to the lower portion of the transom on the inside you need to do the same thing to it.
 

BADPONCHO

Cadet
Joined
Aug 8, 2010
Messages
17
Re: 1990 Gemini 200DCX

Looks can be deceiving. Have you tested the transom??? If/When you remove some decking you need to "Core sample" the stringers to ensure they are good and if you can get to the lower portion of the transom on the inside you need to do the same thing to it.

That was the plan for today and tomorrow. The overall plan was to at the very least strengthen the transom whether it needed it or not, being a 20 year old boat I'd rather be safe than sorry. Most of the innards will be gone over today and tomorrow.
 

BADPONCHO

Cadet
Joined
Aug 8, 2010
Messages
17
Re: 1990 Gemini 200DCX

Strengthen the Transom????

Thicker wood, better materials, stuff like that. Strengthen the internal pieces. Don't ever plan on taking her up to 80+ again but its nice to have the piece of mind that it is better than factory was.
 

eclark53520

Petty Officer 2nd Class
Joined
Sep 2, 2010
Messages
174
Re: 1990 Gemini 200DCX

Thicker wood, better materials, stuff like that. Strengthen the internal pieces. Don't ever plan on taking her up to 80+ again but its nice to have the piece of mind that it is better than factory was.

If the actual transom itself is rotted, adding wood to the inside isn't going to help much when it's attached to a rotted transom...

It's like trying to build a house on mud. You can use all the material you want, it's still going to sink.
 

BADPONCHO

Cadet
Joined
Aug 8, 2010
Messages
17
Re: 1990 Gemini 200DCX

If the actual transom itself is rotted, adding wood to the inside isn't going to help much when it's attached to a rotted transom...

It's like trying to build a house on mud. You can use all the material you want, it's still going to sink.

Transom itself was never in question for me, the inside was however. I took the boat up to a repair shop and they said that it was in GREAT shape, especially for the age. Will edit this post with pictures after dinner!
 

eclark53520

Petty Officer 2nd Class
Joined
Sep 2, 2010
Messages
174
Re: 1990 Gemini 200DCX

I would have it core sampled anyway. That way you know.

Sitting outside for that many years it's possibly rotten.

JMO of course
 

BADPONCHO

Cadet
Joined
Aug 8, 2010
Messages
17
Re: 1990 Gemini 200DCX

I would have it core sampled anyway. That way you know.

Sitting outside for that many years it's possibly rotten.

JMO of course

Had a few tests done, just about everything was PERFECT, the ONLY issue that the boat has is the boards that were used to hold the phone in place while being poured are flaking. These are not connected to anything.
 

BADPONCHO

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Joined
Aug 8, 2010
Messages
17
Re: 1990 Gemini 200DCX

Update of day two! So I missed pictures yesterday but I went and took some earlier today.

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rambo2000

Recruit
Joined
Apr 17, 2012
Messages
1
Re: 1990 Gemini 200DCX

Update of day two! So I missed pictures yesterday but I went and took some earlier today.

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How is the restore going? I have the same boat and having the carpet replaced. How long is yours and can you give me the measurements for the windshield? Hard to find
 

BADPONCHO

Cadet
Joined
Aug 8, 2010
Messages
17
Re: 1990 Gemini 200DCX

The restore has been halted due to weather here in Michigan but I will be jumping back on it tomorrow, nice to have no rain for once! Mine is the 20ft, 96" beam. I'll take some measurements as soon as I find my windshield again, its in the back of the shop with the rest of the stuff. I will actually be replacing mine with a Bass Tracker windshield that will be trimmed to fit properly. I did a similar thing on my 17' Fish-N-Ski and it came out looking really good.
 

BADPONCHO

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Joined
Aug 8, 2010
Messages
17
Re: 1990 Gemini 200DCX

Day three of the Project Poncho build was a day of hard labor, though you may not see it we have spent many hours scraping the aluminum lids until they became spotless, the fiberglass proved to be a different beast entirely.

When I first began scraping on the fiberglass flooring it came off extremely easily after being exposed to the open air. While the large majority of the rear deck, lids included, were incredible easy to remove the glue there was a couple of curve balls when it came to the fiberglass. It seemed as though the glue had bonded with the glass resulting in me having to sand off the excess until it became even with the fiberglass.

Tools used:

14-in-1 tool - $6

Acetone (Not needed for a majority of it but may come in handy) - $7

100grit sandpaper (Never hurts to have extra sandpaper) - $10


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After
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BADPONCHO

Cadet
Joined
Aug 8, 2010
Messages
17
Re: 1990 Gemini 200DCX

Day four was spent scraping the front deck, this was best done by scraping it dry with the 14-in-1 tool then following it with the acetone. The acetone works for you in two ways, it helps to soften to glue and it also cleans the fiberglass allowing you to see spots of glue that you may have missed. After I did a quick move around the deck with the scraper I then used a broom to get any of the fine debris out of the way so that I could better ensure I cleared off the loose glue fibers. The last step of the day was to use a paper towel that I put acetone on to make one final check for loose glue before calling it good for the day.


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BADPONCHO

Cadet
Joined
Aug 8, 2010
Messages
17
Re: 1990 Gemini 200DCX

Hey Guys and Gals!

We finally got out of our financial slump and picked up a new-old 1986 Johnson 200! The motor was cosmetically rough but the top end was rebuilt with only 5 hours on it! Check out the transformation! The hull is going off for paint over the next few days then we can keep on goin'!

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