1993 Chaparral Gemini 190: Chronicles of a New Boat Owner (Deck Rebuild) [SPLASHED June 2018]

[bpounds1991]

Haha I’m sure my wife’ll get a kick out of it later! I found out my dad has the flu so we’ll have to see if he can make it or not this weekend, but either way I’ll at least get the transom and stringer templates done. Tomorrow I’m picking up my coworkers jigsaw; this week has been a little slow and I’m trying to pick back up more on the work. Between my wife and I getting sick it’s just been a lethargic week lol.

 

[bpounds1991]

Thanks hvymtl939, splash goal is some time in April at the latest.

 

[bpounds1991]

Moving right along with some of the work we got done this morning. My coworker came over with the intentions of doing the stringer templates, but instead we skipped straight to making cuts. Finished the transom and both stringers, he'll be coming back next weekend to do the bulkheads while I make templates this week. My biggest question is with the transom. Do you pre-drill the holes, glue, then glass? Or do you glue, glass, drill?

 

[chevymaher]

Looking good.

I put the transom in then drilled. Made sure everything fit. Then resin on a Q-tip and got it all in there wet it down. Then used a wooden dowel to stuff some CSM strands in. Then run the bit through clean it out. Then another coat of resin just in case. Then GM4200 on everything putting it together.

Seeing as factory they don't do anything at all. I don't think there is a wrong way. Just get it sealed.

 

[bpounds1991]

Sounds good, just wanted to double check and make sure. Once this rain finally stops next week I'll get some more work done and hopefully have a ton to update next weekend. Tax return comes within 3 weeks, as does my trip to the composites store :laugh:

 

[Baylinerchuck]

Drill the holes after the transom wood is in for sure. If it were an I/O, you’d cut the keyhole first, but dril the mounting holes once installed. The problem in predrilling is getting the hole angle through the transom correct. A portable drill guide helps accomplish this once the transom plywood is glued and clamped.

 

[bpounds1991]

Thanks BC, that's what I had in mind I just started to overthink it a little too much lol.

 

[Baylinerchuck]

Sure sure. Great progress BTW.

 

[bpounds1991]

Thanks! Trying to keep things moving along as quickly as possible without getting ahead of myself and making a mistake. Weather is looking much better for this week (no rain until next Sunday fingers crossed) so I'll have all the bulkheads measured and templates done before cuts are officially made next weekend. I'll be grinding the rest of the deck lip out throughout the week as well, and at that point pretty much the only thing I'll be waiting on is the resin order from Charleston here in the next 2-3 weeks.

 

[kcassells]

Don't forget to keep the wood off indirect contact with the hull. It creates a hard spot but you prob already know that.:joyous:

 

[bpounds1991]

There is a small gap at the moment between the transom wood/fiberglass, I'll be using PL to attach that here in the near future. The stringers are sitting at height currently but we will be adding 1/4" pieces of styrofoam every few inches to keep it raised off the hull.

 

[kcassells]

Perfect.

 

[bpounds1991]

Went and got a little bit more grinding done this morning. The bulkhead templates were giving me some frustration so I just decided to revisit that tomorrow morning lol. All but about 2 feet of the deck lip is gone, I'll be smoothing that all down tomorrow as well.

 

[oldrem]

Looks great. Not looking forward to grinding on my Ouachita, so will probably rebuild the Sylvan first lol. Still a couple months of frigid weather here to prep first.

 

[bpounds1991]

Thanks oldrem, the weather is so iffy here at the moment. Highs of 50s but lows of 20s during the night lol, when I went out this morning it was 28 so it wasn't the most enjoyable. I'm just trying to finish all this stuff before the tax return comes so I can move on to the next "phase" with no hiccups.

 

[oldrem]

Our highs will be mostly in the teens and 20's for at least the next 2 weeks with several overnights in the single digits. Anxious for this crap to break

 

[bpounds1991]

I don't blame you I absolutely HATE the cold lol. Got out and finished 2 bulkhead templates this morning, not the prettiest but they should give us a starting point on the wood Saturday. I just found out our tax return comes in 4 days, so I'll be making that Charleston trip sooner than expected

 

[bpounds1991]

Bulkhead templates are finished, not the best work but it should give us a good enough start to cut the real deal tomorrow. Also spoke with the composites place today just to have a few last questions answered before I make the big order. So far this is what I have:

-15 Gallons Polyester Resin (comes with hardener)
-5 Gallons White Gel Coat (Might be overkill, but I'll be doing multiple coats and covering the entire deck, the above deck portion of the bottom cap, as well as bilge, transom, ski locker, gas tank area. 43$/gal or 170$ for 5 gallons)
-1 Gallon Styrene Surfacing Wax
-3 Pounds of Cabosil
-2 LB Density Expanding Foam (need to do a few measurements to finalize the exact amount needed)
-15 yards .75oz CSM (Using a 19 oz mat, I feel like 1.5oz will be overkill/soak up too much resin)
-4 Pounds of 1/2" chopped strand fibers
-Various size "bubble buster" fiberglass rollers

Should about cover it I believe? I've got most of the other stuff already; mixing sticks, mixing containers, etc.

 

[JASinIL2006]

Sounds about right.

 

[bpounds1991]

Unfortunately my phone died or I would've had a few more pictures today. We were able to finish 2 bulkheads after a headscratching half hour of trying to figure out why the boat was 1 1/4" off from side to side. I thought it was because it was parked slightly downhill in our driveway and slightly off on the trailer, but even after straightening it up on the trailer we weren't able to make it much more level. After that we decided to go ahead and make it level from side to side in the boat versus "level" with an actual level. Very confusing but I think it worked out in the end...bulkheads are even side to side (exactly 1" below deck height to account for 1/4" foam, 1/2" deck, 1/2" of fiberglass).