76 Glastron Sportster Restore

[Wallman67]

Picked up a Glastron tri-hull in the early spring. I had in mind of fixing it up as a fishing boat, little did I know just how much "fixing" it really needed. After reading these forums for the past 6 months, thinking should I or shouldn't I, I've decided to give it a go as a winter project. I've gutted the boat this week and removing the outboard this weekend ,maybe start taking off the cap and deck etc.

Here's my first of many questions to come....after I remove the cap do I work on the bottom shell while it's on the trailer, or do I remove the trailer and work on the bottom shell on the garage floor, or do remove the trailer and rest the bottom shell on some sort of craddle ? Also when I'm removing the deck, stringers, foam, transom, is the shell strong enough for me to climb in and walk around and move around or is it too fragile ?

Warning more to come, it's just begining........

Here is a photoshop link to all the work

http://s936.photobucket.com/albums/ad202/Wallman1967/1976 Glastron T166 Restore/

 

[kevman]

Re: 76 Glastron Sportster Restore

Welcome to Iboats. I also own a Glastron and I look forward to seeing your progress. I have read where people leave them on the trailers to keep the hull from widening after you take the cap off. I dont want to give out a lot of advice though because I am not an expert at this. However, there are many nice people on here who will give you all the help you need. Good luck.

Kevin

 

[Bob_VT]

Re: 76 Glastron Sportster Restore

You can do it either way. Just remember to keep things true. The hull shell will hold you (don't jump into the hull) and be careful that you do not develop a hook. When you re-install the stringers you might have to support the hull from the outside so it is not sagged..... a but tricky but very doable.

 

[Wallman67]

Re: 76 Glastron Sportster Restore

I'll try and post pictures soon. I'm taking off the top and removing the decking this weekend. After I replace the stringers and transom should I put the top back on temporarily to hold the hull true and not develop a hook. Then lay the decking back on. Once the decking is one the top can be removed and it should hold shape.

 

[system-f]

Re: 76 Glastron Sportster Restore

I am going to resinstall my cap on my 71 Glastron to hold the Hull true while I put in the transom/stringers/deck. The hull is a bit think on the sides for me to feel comfortable doing all this work without the cap to support it. If you glastron is like mine and has screws it is very easy to pull the cap.

 

[Wallman67]

Re: 76 Glastron Sportster Restore

I think thats what I will do also. I removed almost all but stop short at the transom with the insulation in the corners for now, hoping this will help support the hull. I figure I'll repair the hull, install new stringers then put the cap back on before the new deck, to again support the hull. Once the deck is back on, I will remove the cap again then do the transom. I'm going to re-paint but can't decide to do it before or after the deck install. Here's what I've done so far...... As you all can see I also cut thru the hull with my trusty skill saw and grinder.. not too much skill required there. Having never fiberglassed before this should be interesting..........

 

[Wallman67]

Re: 76 Glastron Sportster Restore

I also noticed that once the wooden transom was removed the hull shell looked all cracked, probably from stress. As shown in picture. It also has the wood grain imprinted. Should I continue to sand it down till the wood grain imprint and cracks are gone ? I was thinking of glassing it with 1708 first then putting the new transom. The re-glassing would re-strengthen the stress cracks.....Also to repair the two known cuts, I will look closer for more after it's cleaned better,
I'm thinking of feathering out the cuts from the outside. Then laying some 1708 fiberglass on the inside for backing. Then patch the outside with multiple overlapping fiberglass, just don't know exactly what type yet or if this is the best repair. I'm painting the hull after so I'm not worried about outside matching at this point. Lastly in serveral places inside the hull there's build ups of what I think is resin,like should in the picture, that's all cracked. Is it best to grind the cracks all down to the hull fiberglass or leave it ?

 

[Wallman67]

Re: 76 Glastron Sportster Restore

Flipping the boat.....first I raised the front and tied it off..

http://i936.photobucket.com/albums/ad202/Wallman1967/1976 Glastron T166 Restore/BoatPictures001.jpg

Then I tied off the back thru the drain hole..

http://i936.photobucket.com/albums/ad202/Wallman1967/1976 Glastron T166 Restore/BoatPictures002.jpg

I lowered the front and removed the trailor...

http://i936.photobucket.com/albums/ad202/Wallman1967/1976 Glastron T166 Restore/BoatPictures003.jpg


One helper flipped the boat while I use camera...

http://i936.photobucket.com/albums/ad202/Wallman1967/1976 Glastron T166 Restore/BoatPictures005.jpg

Boat flipped and lowered to ground.

http://i936.photobucket.com/albums/ad202/Wallman1967/1976 Glastron T166 Restore/BoatPictures006.jpg

Now to address bottom of hull...

 

[Wallman67]

Re: 76 Glastron Sportster Restore

I have to repair a cut made by my skill saw...I'm going to repaint the hull so I'm not too worried about looks as it will be painted.

http://i936.photobucket.com/albums/ad202/Wallman1967/1976 Glastron T166 Restore/BoatPictures008.jpg

I have two idea's ?

1) Tape wax release paper to outside. From inside use strips of woven and epoxy to cover the cut, overlapping each by an inch. 3-5 layers. Then after it dries, remove wax paper and finish outside with thickened epoxy and sandpaper.

2) Grind around cut, tapering out gently maybe 5-6 inches. Again layering woven and epoxy over the grinded out cut.

Basically same except was wondering if it was really neceassary to grind around the cut.

 

[Wallman67]

Re: 76 Glastron Sportster Restore

I also have some chips and damaged gel coat. Since I'm re-painting anyways, what's the best way to repair ? I was thinking of using thickened epoxy for the chip and sanding. For the damaged gel coat I was thinking of sanding all the damage gel coat off to the fibergass. Then filling the area with thickened epoxy. Should this work ?

http://i936.photobucket.com/albums/ad202/Wallman1967/1976 Glastron T166 Restore/BoatPictures008.jpg

 

[rescue1m]

Re: 76 Glastron Sportster Restore

Well, sir, I'm just getting started on mine, it;s a 75 glastron and so far i've got it separated, the top is on saw horses and the bottom was left on the trailer. Unlike you i have to work out side dont have a nice garage to work in, now i dont know about you but mine has no time table so im going to hit it when i can. Heck i might be asking you for advise, but so far from what ive seen of yours too, im going to keep some on the stern and bow, My main issue is the rotted wooden support down the middle

 

[Wallman67]

Re: 76 Glastron Sportster Restore

Next I built a cradle to support the hull while I work on it.

http://i936.photobucket.com/albums/ad202/Wallman1967/cradle.jpg

http://i936.photobucket.com/albums/ad202/Wallman1967/cradle2.jpg

I put caster's wheels on the bottom so I can move it around the garage.
I'll take another picture later, but the craddle also holds the boat when I flip it the other way to work on the outside bottom. It just does support it so I climb in...

 

[Wallman67]

Re: 76 Glastron Sportster Restore

I had the right idea on this repair, but I might have to modify my repair slightly. Remember this.....

http://i936.photobucket.com/albums/ad202/Wallman1967/1976 Glastron T166 Restore/BoatPictures008.jpg

Now I ground both sides of the hull around by saw cut out roughly to a 12 to 1 bevel. I taped and supported release cloth to the outside of the boat. On the inside of the hull using 6 oz cloth I cut out 3 peices of fabric exactly to the size of the hole. Wetted them out with Epoxy and laid them inside the hole. Next I cut 3 more peices of 6 oz fabric , one 2 inches larger, one 4 inches larger, and last one 6 inches larger. Wetted them out and layed over the hole. Now this is what I have.

http://i936.photobucket.com/albums/ad202/Wallman1967/IMG00023-20101127-1218.jpg

I repaired another saw cut/hole the same way at another spot.

http://i936.photobucket.com/albums/ad202/Wallman1967/boat002.jpg

Now it's this....

http://i936.photobucket.com/albums/ad202/Wallman1967/IMG00024-20101127-1218-Copy.jpg

I'm thinking I did this part of the repair properly, but I feel I could have used a higher strenght cloth. The local fiberglass shop has 10 or 12 oz cloth in stock but sold me 6 oz cloth with the epoxy saying it was easier to work with and would do the job. I'm second guessing it now that's it done. For peice of mind I'm going to pick up some 10 or 12 oz cloth, he only carries 1708 in a 4 inch tape, and go over the the inside patch a couple of times with the heavier cloth.

Also to make up for this , I'm thinking of repeating the repair on the outside of the hull once I flip the boat again. Repeat the cut out of 3 layers inside the hole with the heavier cloth before a couple on the outside . Then fair it with the rest of the hull.

 

[Wallman67]

Re: 76 Glastron Sportster Restore

I also decided to try and repair the outer edges of the boat. The gel coat in several places had chips and deep gouges. I gently used a dremel to grind away the area's and in a found some small holes. So I figured the best way to repair this is from both sides just like the two holes I just did. On the inside of the boat I layed a 6 inch peice of 6 oz cloth , then a 4 inch 6 oz cloth over it right in the wall hull joint. All the way down both sides of the boat. Here are two pics.

http://i936.photobucket.com/albums/ad202/Wallman1967/IMG00026-20101127-1219.jpg

http://i936.photobucket.com/albums/ad202/Wallman1967/IMG00027-20101127-1220.jpg

Again I used the 6 oz, after I pick up some 10 or 12 oz cloth I might go over it once with that. I'm thinking of picking up some 1708 4 inch tape, I'll use it for the transom joint, and put it on . I'll think on it.

 

[Wallman67]

Re: 76 Glastron Sportster Restore

The boat also has a bad case of keel rash from beaching the boat. In one spot the fiberglass is scuffed up bad.

http://i936.photobucket.com/albums/ad202/Wallman1967/boat008.jpg

http://i936.photobucket.com/albums/ad202/Wallman1967/1976 Glastron T166 Restore/BoatPictures009.jpg

http://i936.photobucket.com/albums/ad202/Wallman1967/boat001.jpg

I ground away the gel coat around the bad areas and will treat the last one like a hole. Inside and outside repair. Now I haven't done it yet but I was planning on glassing the keel of the boat down the whole length inside and outside. On the inside just for peice of mind. Maybe 3-4 layers going from big to small. Thinking of 12, 10, 8, 6, 4 layers of cloth. Don't know if 6 oz is enough , or maybe 10-12 oz cloth.. Was going to do this on the outside as well, after I repair the hole like delamination.

I figured this will add protection since most of the gel coat is already gone, and I'm have to repaint the hull anyways this protection is needed.

 

[rescue1m]

Re: 76 Glastron Sportster Restore

Well i put my hull under a half assed carport and took out all but the foam blocks. (I didnt have a nice garage todo all this in lol) j/k. Still working on trimming down were the plywood and stringers were and only put one 3" hole (in length only) on my first cut. But my question is how do you replace those foam blocks on the (I think its the stern) the back in part that sat on either side of the transom. Which btw came out pretty easy.

 

[Wallman67]

Re: 76 Glastron Sportster Restore

Right now I'm going to leave them. They help hold the shape of the back corners. With the stringers, deck, and cap off I figure I need something to help hold the shape other than the cradle. My plan is once my hull is repaired, stringers glassed, deck replaced, then I will do the transom and deal with the foam in the corners. I have dug out the wet bad foam out of the bottom, but really most of it is good. I had to also remove some of it so I could get to the back to repair a hole or two in the hull. Most of it is still in place.

I marked the outline of where the foam was before I did anything. I plan on framing out that area with rigid foam from Home Hardware. Glue it into place with PL400 or thickend epoxy. Then filling in the missing voids with either 2 part pour in foam or foam in can. I'm leaning towards pour in foam, like to play around and try it.

Kinda how also I'm going to replace the foam between the stringers. Frame and fill the large area with rigid foam or pool noodles and stick it all together with pour in foam.:redface:

Ya garage is nice, but still not much for heat inside when its minus 30 outside With the cold weather hitting I finally have time to post here and re-think and research my project. Once it gets closer to 0 then I'll fire the little heater up and cut some stringers. If somehow I can get two or three heaters going and get the temperature to 20 I'll do some glassing...

 

[rescue1m]

Re: 76 Glastron Sportster Restore

Well, I've had to hold off on my hull for now, other priorities to deal with, but as soon as i can i will hopefully finish cleaning out the hull and possibly the foam blocks. But now i know about pour in foam i think i will remove the foam blks. Will see what happens when i do finally get the time.