1994 Starcraft Transom Repair

[eville]

We have a 1994 Stardeck 240. I started a repower from a 60 2
Stroke merc to a 2013 Honda 90 today. I discovered my plywood is rotting and when attempting to tighten the lower transom bolts the aluminum was collapsing. It appears that Starcraft welded the aluminum solid after installing the play wood. Any suggestions on how to replace this plywood? I guess I’ll cut the top off the transom plate replace the plywood and bolt/ epoxy a piece of angle aluminum over the top. Doesn’t seem like tig welding the metal back on would be good for the wood. Any thoughts appreciated.

 

[ahicks]

Do you have access to a good welder?

My last transom project, on a 17' aluminum boat, had me using an angle grinder to cut the top off of the aluminum transom to access the ply wood, dig all that old crap out (taking quite a bit of time) fabricating/laminating ply together for a new transom the right size and thickness, then taking it to my favorite welder to have the top welded back on.

He took one look at it and told me NEXT time, cut the entire transom off and get it all cleaned up, then bring it to him so he could fab an entire new transom - with NO PLYWOOD in it!

Lesson learned here.....

You could go that way if you have somebody that's willing to work with you like that, having them fab an entire transom from alum. OR canvass your local welders with those pictures in hand for THEIR ideas on how you should proceed. If you have access to an angle grinder, the necessary cutting is not that difficult. Then you can do most of the work and take it to them for final welding. Just get somebody lined up before proceeding. -Al