67 Lone Star Restoration

Parmaboater

Cadet
Joined
Apr 21, 2009
Messages
8
Hello everyone Still pretty new here but so far I like the advise I've been given and this sure looks like the place to share in what I hope is a successful restoration!
I guess I should start off with what I have as the title tells you its a 1967 aluminum hull Lone Star Del Ray (what the boat title says) And the Plate on the hull says its made by Chrysler. This is my first boat but I realistically don't expect to have her on the water till next summer unless I fall into some cash. I bought the Boat, trailer and motor for $350 At first it looked like all I had to do was replace the plywood deck and side panels but after tearing away the rotten plywood and the old glass I find out that the boat also has inhabitants, a nice colony of carpenter ants! They have made a part of the foam into swiss cheese and after removing some screws, plates and glass also turned my transom into swiss cheese as well. Surprisingly none of this scares me to much but I cant say the same for my wife.

So anyways here are some pictures of whats ahead for me.
P1090185.jpg

P1090186.jpg

Brackets that are riveted to the hull that screw into the transom.
P1090191.jpg

The cap on the top of the transom has 6 screws in it and a drain hole.
P1090193.jpg

I have yet to get up into the bow but the glass still looks good. Its been out of the elements unlike the rest of the deck aft of the dash.
P1090190.jpg

Swiss cheese foam right in the middle of the boat.

I've read a few threads on replacing the transom but I have a question or two. Should I remove the back exterior aluminum transom cover or just try and remove the top cap, pull out the plywood and replace it? If I drill out the rivets and replace the wood in the transom are there any special rivets I need to buy to replace the old ones I drill out or will any kind of aluminum rivet of the appropriate size work? If I try and remove the top cap there will be only 12 rivets to remove if I remove the entire transom there will be a few hundred.

Next question has to do with the foam the ants have tunneled into. Should I cut out the bad parts and when I lay my new plywood deck down just drill holes and pour in the 2 part expanding foam or rip out all the foam and replace it all? Most of it is still very solid, I can stand on it and there is no give at all. I have yet to price the foam and I would like to do this restoration minimizing expense but obviously not quality.

As soon as I get a friend over to help me remove the motor I can start on removing the old wood in the transom and hopefully I can try the easier of the two options and also depending on the advise given on the two.
 

S. Toth

Petty Officer 3rd Class
Joined
Apr 20, 2009
Messages
98
Re: 67 Lone Star Restoration

It would e best to just rip everything out, and lay new foam.:) Good luck.
 

tmcalavy

Rear Admiral
Joined
Aug 29, 2001
Messages
4,005
Re: 67 Lone Star Restoration

Just did a boat similar to yours...pix at acmeoutboards.com
Pull out the floor dust, that's all you have in there, yank the old foam, clean it out and buck all rivets. Then put some Gluvit on the inside hull, to seal it. Then replace the foam, drop in a new deck and start refitting. The demo is the nastiest part of the job. It's best to pull the splashwell...makes access for a new transom easier, and most aren't that hard to pull.
 

sschefer

Rear Admiral
Joined
Nov 13, 2008
Messages
4,530
Re: 67 Lone Star Restoration

I'd put them ants on the payroll.. There must be 1000 posts on how to remove the foam. Mother nature just made it look easy.

You've got a great project and by taking your time you can easily bring this one back to life.

The first step is to strip it out completely and then assess the hull integrity. You need to check every rivet, tighten them where needed and then, as was previously mentioned, go to town with the GluVit.
 

Bob_VT

Moderator & Unofficial iBoats Historian
Staff member
Joined
May 19, 2001
Messages
26,065
Re: 67 Lone Star Restoration

My Starcraft is a 66 and seeing the condition of your plywood makes me VERY lucky mine is intact.

Too bad you don't have access to a fire hose..... I bet if you tipped it up most of that stuff would wash out!
 

Parmaboater

Cadet
Joined
Apr 21, 2009
Messages
8
Re: 67 Lone Star Restoration

Just did a boat similar to yours...pix at acmeoutboards.com
Pull out the floor dust, that's all you have in there, yank the old foam, clean it out and buck all rivets. Then put some Gluvit on the inside hull, to seal it. Then replace the foam, drop in a new deck and start refitting. The demo is the nastiest part of the job. It's best to pull the splashwell...makes access for a new transom easier, and most aren't that hard to pull.

Splashwell? Is that the area just in front of the transom that looks like a little tub with the two drain holes that go back through the transom? If so thats part of the "cap" I was describing that I wanted to remove to get the wood part of the transom out. The new transom should slide right in when I get that off. One question I forgot to ask was is there a good online retailer to go through that has everything I'll need like the Gluvit and 2 part foam or is it cheaper to go to local retailers? Sorry for the seemingly simple questions but I'm completely new to all this. Thanks
 

sschefer

Rear Admiral
Joined
Nov 13, 2008
Messages
4,530
Re: 67 Lone Star Restoration

Shop local whenever you can. Right now your local community needs your business more than ever. If you can't find it locally, you can safely shop at the IBoats store, West Marine, Cableas and Overton's. They all have good reputations for not ripping people off. IBoats pricing is sometimes better than others.

A lot of folks shop on Ebay and a few posters are regular sellers. Just be smart and if it sounds too good to be true then look elsewhere.
 

Parmaboater

Cadet
Joined
Apr 21, 2009
Messages
8
Re: 67 Lone Star Restoration

A few updates to my progress. I removed the splashwell then the rotten and chewed up transom board. When I dug into the transom a bunch of ants poured out. Not a whole lot but enough. Then later in the day my nephew say there are ants IN my sun room so when I go inspect I see they are carpenter ants like the ones in my boat so the wife and I run to walmart grab some bug killer for indoor and out and spray the sun room. When I look in the boat again at the bow I see there are ants under the remaining foam and wood so I grab a shovel and pry up some more wood and thats when all hell broke lose I first saw a few dozen but as I pulled more wood up it turned into a few hundred then a few thousand! Infestation to say the least. I quickly grabbed the lawn bug spray and started to wash down the inside of the boat and luckily killed them all. I took pictures of what they did to the foam which in the long run did save me a few more min of chipping away at the foam.
P1090225.jpg

On the right you can see where the foam was, the ants had completely chewed it way. When I pulled up the big piece in the bow almost nothing was still attached to the hull.
P1090224.jpg

P1090222.jpg


Here is what the transom looked like when I took the splash well off.
P1090207.jpg

P1090208.jpg

The hull after taking a shovel to the foam to pry it up.
P1090227.jpg


Now I have to get in there and somehow get the rest of the foam up to make the hull nice and clean without banging on the rivets to much. I was thinking of using a 4" plaster knife to break up the bigger pieces then a brass wire wheel on my drill to do a good cleaning.

I still need to remove the dash and windshield and a few pieces of hardware but the foam removal nightmare is over for the most part.
 

CBGale2

Lieutenant Junior Grade
Joined
Apr 22, 2009
Messages
1,026
Re: 67 Lone Star Restoration

I had to deal with a carpenter ant infestation on my boat im redoing too. I didnt have any idea they were in there. I was tearing out the old rotted wood benches, I couldnt get a couple of the bolts out so I just grabbed the claw of my hammer under the bench and lifted up to break it in half, wood split in half and like you said....:eek: all hell brooke loose! Did the same thing, grabbed the bug spray and started the killing, when that ran out, starting fluid spray worked ever better. :D
 

tmcalavy

Rear Admiral
Joined
Aug 29, 2001
Messages
4,005
Re: 67 Lone Star Restoration

Good work...you're almost through the nasty phase of stripping/cleaning.
 

CheapboatKev

Vice Admiral
Joined
Oct 4, 2008
Messages
5,813
Re: 67 Lone Star Restoration

Wow..talk about pursueing your vision...
I woulda dump a gallon of diesel in there and lit em up!

Thank the Lord thats an alum hull you got there...glass or wood would have been a total loss...

Keep at it and I think you hafta paint it yellow with ears and a tail like the Truly Nolan cars..lol
 

Parmaboater

Cadet
Joined
Apr 21, 2009
Messages
8
Re: 67 Lone Star Restoration

Whew! Foams out! Windshield is off along with the hardware. I had to call it a day after I pinched the hell out of my hand with the pliers when they slipped off a gourmet I was trying to remove. I also found a leak in the keel when I was washing the hull down on the inside. Doesn't seem to be a big problem but there also doesn't seem to be any type of sealer inside the keel seam which probably didn't help the waterlogged foam any. Anyways just a few bits and pieces to clean here and there some sanding then I can get on with the next item on the list.

P1090300.jpg

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Looking at the hull close up if the boat had sat there a year or so longer the formic acid from the ants would have eaten a hole right through the aluminum. Its got some pretty bad pitting in a few spots.

I also called around for some Gluvit and 2 part foam and wow! local retailers are charging double what online retailers are for both products. Looks like I'll be making more than a few online purchases.
 
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