1996 Key West Renovation

Bsquared

Seaman Apprentice
Joined
Aug 30, 2007
Messages
39
The boat had been on a lift, and a tropical storm turned out to be much more damaging than originally forecast. By the time the owner realized it was going to be bad, the power was out. Then the waves started to build, and all they could do was watch it beat itself against the pilings. After the lift collapsed, the boat washed up on a sandy beach. They used a wrecker to drag it up the beach and back onto the trailer. The trailer appeared to be in good shape, and the front half and bottom of the boat looked very good, other than one short section of damage on the starboard bow. The back was chewed up more than you can see in these pictures; the whole port deck stern quarter was hanging on by a thread and was flopping around in the breeze on the drive home. The gray tube you see on the starboard side is a plastic pipe they use to carry control lines back to the rear of the boat; it was gouged and beat up but it did protect the stuff inside. Key West uses NO wood in the boat, so I wasn?t worried about rot. All the electrical stuff in the back of the boat was corroded to nothing (typical when submerging a live battery in saltwater). The transom looked and felt solid with beefy stringers and a solid motor well structure, and the motor looked very steady on the ride home. There were a few gaping holes where the swim platform had gotten ripped out. The motor looked like a very dedicated vandal had taken a hammer and smashed EVERYTHING on the motor. No plugs, no coils, no electronics, no temp sensor, and most of the carbs gone as well. However, the lower unit (and prop) looked pretty good. My thought was here is the cheap fishing boat I was looking for; quick and dirty repair of the sides and I?ve got a boat I don?t need to keep clean or worry about dings. Self-bailing, no wood, no carpet, easy to trailer, and nice-looking (well, after some work).
 

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Bsquared

Seaman Apprentice
Joined
Aug 30, 2007
Messages
39
Re: 1996 Key West Renovation

We hoped we could find a cheap engine with a blown cylinder, and just swap in our good internals, but when we took the block apart, we found that the saltwater had gotten inside and had rusted everything. OK, we need a new motor. The steering rod had also been bent; it was a real job to get it out of the motor tube. I didn?t have any confidence we could get it straight enough to work in another motor, so I had to buy a new steering cable as well. Fortunately the engine controls were still usable, even if not quite in their factory shape.

As the damage was not strictly structural, I wasn?t too concerned about strength. I bought some ?? plywood, and coated everything with two coats of epoxy. Then I cut out panels for the outside hulls, ground a bevel on the edges of the wood, cleaned up the damaged area, ground down to good glass all around the damage, and screwed and glued the panels on the hulls. I used 5200; took a while to set up but provided a sealed strong connection. I did the same on the inside. On the port side, the boat had a built-in molded plastic rod holder. Part of this was now missing and the rest had a big crack. I added a plywood piece on the inside to cover and contain the crack, and just extended the outside piece to cover the missing part. I COULD have tried to find or buy a new plastic piece, but did I mention that I was doing this cheap?
 

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Bsquared

Seaman Apprentice
Joined
Aug 30, 2007
Messages
39
Re: 1996 Key West Renovation

Once I had the sides built up, I added some 1x2 stringers to give me something to screw the top deck into. I also ran one 1x2 down the middle of the deck for added strength. I had to align the remaining stern quarter lids to match with the new deck. The boat originally had a small rail on the inside of the deck; I merely cleaned that up and added a rounded transition piece into my flat deck. The two rails are not equal length on both sides now, but most people won?t notice.

Added the top deck and a few odds and ends of wood as needed. Tabbed the wood to the original glass around all edges with fiberglass tape and epoxy, then added two layers of glass cloth /epoxy over all the wood. A fairly light construction, but probably as strong as the original glass except in impact maybe. Plenty strong to walk on; we?ve had some rough rides and some piling impacts and no cracks or groans or movement. Filled in other holes and gaps with glass cloth as a backing and Tiger Hair as a filler. Ground it all down in a hurry, because it was getting close to fishing season. Found some spray paint that was almost the same shade: bam, it?s done. The rub rail was still in one piece although very chewed up in spots. After a lot of work in removing the broken-off screws, we put that back on. About $2K in wood, glass, epoxy, hatches, gas tanks, SS screws, and a new Bimini (the owner had ?salvaged? almost ALL the screws out of the boat before he sold it).
 

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Bsquared

Seaman Apprentice
Joined
Aug 30, 2007
Messages
39
Re: 1996 Key West Renovation

One of our neighbors had a ?77 Evinrude 75 HP; had been sitting for several years. Cleaned up the carbs and it started right up. Nice thing about going from 96 Johnson to 77 Evinrude is that everything plugged right up. I wasn?t sure what shape the internal tank was in, so we just used 6 gal plastic tanks. Not enough motor for the boat (top speed around 27), but it got us through the fishing season for FREE. Pretty worthwhile as you can see from the pic. This spring I found a very nice ?98 Evinrude 130 HP. This one required an adapter for the wiring, but that was an easy mod. I drained and flushed the internal tank so I could hook up the VRO system (not mixing oil is great!). Now she runs 40+ and pulls skiers no problem.

Rough job up close, but a nice solid boat that rides great, and when you back up 20 feet, it looks great  Still a lot less invested than comparable boats I see for sale ($500 original cost with trailer, $2K in parts, $2k for motor). I MIGHT even do more filling and sanding this winter, and then do a real paintjob.
 

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Labman

Petty Officer 2nd Class
Joined
Jun 30, 2008
Messages
117
Re: 1996 Key West Renovation

Like he said!^^^^^^Good Work!
 
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