'93 Sea Ray 200-BR rebuild (stringers/floor/engine)

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

Wow, how did we ever survive without E-bay. The original carb was pretty much destroyed due to ater sitting it. I turned to E-bay and purchased a nice looking carb. It came in yesterday and I installed the rebuild kit today. Put the new haert and lung on top of the 305, pumped a little gaas up to it, and crossed my fingers. Had a little trouble with it gettting fire at first but that was quickly fixed. Tried it again and the ole Sea Hag jumped to life after a long rest. It probably been over a year since it has been cranked. The temp was steady at 145, the oil pressure looked good at 35 psi, and it appeared to be charging as well. The trim gage did not work so I will have to see what is going on there. Now that I know it runs, I can get back to getting the floor out of the boat. Tomorrow, I will make a trip to Texas Parks and Wildlife to get the title transferred into my name. I do not want to do to much more to the boat until it is in MY name and it is officially mine. Thanks everyone for the info that you have offered. Thanks, Steven

Engine running from inside the boat:
http://www.youtube.com/watch?v=MfuQ2QWgmDA

Engine runnig from back of boat:
http://www.youtube.com/watch?v=QoDblHCRdLI

Please forgive the video quality. It's just a cheap $80.00 Kodak camera from Wal-mart, but it gets the job done.

 

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

I'm up late tonight (01:15). I start back on nights Tuesday so I pulled the boat up to the fire station to do a little wood work. The new "3 Craftaman circuar saw worked pretty good. At its maximum depth, it will barely cut all the way through to the foam so I did not have to worry as much about cutting the bottom of the hull. I noticed several days ago that when I would step on the back of the floor, water would come out of the old battery box holes. Once I cut the floor out and exposed that side of the hull, the foam was wet and water was in the hull. I do not see any drain holes so the water can't drain to the bilge. Should there be some? I will definatly do the new floor a little different to mount the batteries and other things. From what I could see, the wood towards the back of the boat looks pretty good. I hope and pray that the transom is ok. The front 2/3's is pretty much dust. Including the stringers. My plans are to take the boat to my parents house to remove the engine and freshen it up. This will also give me much needed room to work in the boat. I also still need to cut out the fuel tank to get it out of the way as well. Here are a few pics of what I got myself into. Thanks, Steven

Stringer under the port console and old back to back seat:

Same stringer next to the fuel tank:

Floor just in front of the engine:

Bottom of the ski locker:

 

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

It looks like I am going to have to work this weekend so I will not have time to mess with it to much. May have some time Sunday to try and cut the other side of the floor out. Thanks, Steven

 

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

I finally got a little time off from work and was able to take the boat to my parents house and get the engine pulled today. My little two car garage does not compare to dads 30' X 60" shop. Nice shade to work in and plenty of fans blowing to keep us somewhat cooled off. Since there was no bulkhead in front of the engine, we were able to pull it without removing the outdrive. It was nice just unplgging the wiring harness to get the electical out. I left everything on the engine. It went pretty smooth up until it was time to make the lift. Next time I will remember to pull the dust plate off the bellhousing before trying to remove the engine. I cussed that thing for 1/2 hour before I finally figured out what was holding the motor from coming forward. Now I should have plenty of room to work on the floor. Thanks, Steven

Hot Rod 305 sitting on the engine stand:

Bellhousing with outdrive still in place:

Rear fuel tank bulkhead. I hope the wood is good:

Video of initial cold start. I did not start the engine prior to the video. Just 4 pumps of the throttle and turn teh key.It actually starts pretty good for an engine that had water in it and was in the brink of being siezed up.
http://www.youtube.com/watch?v=bWm3p9bM_dc

 

[Bravo]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

Brother, it looks as if you and I are in the same boat so to speak. I'm doing the same sort of thing with my Invader Bravo. So far I have had to remove the top of the boat and cut every inch of wood out of this thing as it was ALL rotten. Do yourself a favor, invest a couple of bucks into a few of those Tyvek (sp?) paint suits as they will save you the cold shower from fiberglass dust. I also wear a respirator as the dust has to be terrible for your lungs. The suits are hot as hell to wear, but well worth it. Ive gotten the new transom in and have started on the stringers. Tomorrow brings the stink of more resin and the crazy looks I get from my girlfriend as she wonders why I'm going through all of this. I tell her its something I can't explain, but she will understand completely when she gets out there for the first time and feels the air and the wonderful feelings that only the open water can give... Best of luck to you.

 

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

Do yourself a favor, invest a couple of bucks into a few of those Tyvek (sp?) paint suits as they will save you the cold shower from fiberglass dust. I also wear a respirator as the dust has to be terrible for your lungs.

I have about 6 off those suits left for now. They are definatly hot but I can do without the cold shower. I need to see if I can get a look into the transom now that the engine is out of the way. My wife is just like yours Bravo. The only thing that she can see is a boat that needs to become an artificial reef on the bottom af a lake somewhere. Thanks, Steven

 

[Bravo]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

I hear ya... she came outside today and when I poked my head up she said I looked like a crazy alien. I had my respirator on and a tyvek suit with black latex gloves on that were covered with resin and mat fibers. All the while sweat was pouring down my face. I'm sure I looked a little crazy. She told me again that I was nuts and gave me some water before shaking her head and walking back inside.

 

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

I was finally able to make a little progress on removing the old floor last night. I finished up the port side floor removal behind the console last night and started on the starboard side. Made it past the seat area and the trash can was full. It looks like the stringers are going to clean up pretty good towards the back and give me something to splice together with. If all goes well, I hope to make another run at it tonight. When I remove the front part of the floor, what is the best way to support the two consoles? Thanks, Steven

Port side rear floor removed:

Port side mid section under console:

Port side stringer cleaned up good and is rigid:

Starboard side mid section under console:

Starboard side rear floor section still needs to be removed:

 

[Bravo]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

What I did was use a scrap piece of plywood. Brace it against the hull and either screw or prop it to the console. You might be able to use a small ratchet strap and hang it from something above if that's available. A 2x4 might be better in case you need to remove part of the floor and then move the brace so you could get the rest out, while all the time being supported. I hope that makes some sense... good luck.

 

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

What I did was use a scrap piece of plywood. Brace it against the hull and either screw or prop it to the console. You might be able to use a small ratchet strap and hang it from something above if that's available. A 2x4 might be better in case you need to remove part of the floor and then move the brace so you could get the rest out, while all the time being supported. I hope that makes some sense... good luck.

I was thinking of using a 2x4 and making a "T" to secure each console to. I will have to build it before I can remove the rest of the floor that is under the consoles. Thanks, Steven

 

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

Well, it looks like bad luck has finally found me. When I removed the port side floor a few nights ago, the stringers cleaned up good and the transom was ok as well. Today, I cut out the starboard side floor and that's where I found the problems. The stringers were still soft back to the motor mounts and the bottom of the transom is wet and soft. Now, where do I go from here? Do I need to remove the complete outdrive assy. and all of the wiring and hoses to get access to the transom? Thanks again for all of the advise and help offered here on iboats. Thanks, Steven

Starboard rear floor:

Bottom of the starboard transom:

Port & Starboard stringers:

Ski locker floor removed:

 

[Bravo]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

well... i can tell you the truth or lie to ya... lol. The truth is that its ALL gotta come out. You're gonna need to remove anything that's in front of the transom as well as anything attached to it. TAKE PHOTOS!!! It will help upon the reassembly. Make drawings and measurements, clearly label every component and wire you remove as well, and put all nuts, bolts and screws in labeled zip lock bags. I promise to you from experience that your life will be easier. Do it once and do it all to have yourself a strong and safe boat. BTW, be sure to use a respirator when cutting fiberglass. The damage to your lungs is terrible, as the dust never goes away.

 

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

BTW, be sure to use a respirator when cutting fiberglass. The damage to your lungs is terrible, as the dust never goes away.

Thanks for the info. I was hoping not to have to go this far but it looks like I have no chioce. I have been using a MSA half face respitator with goggles and wearing the Tyvek suits while making cuts. This is definately not the time off year to be doing this. Thankfully, I can take it to the fire station and work on it indoors and not in the sun. I start back on nights tonight, so it may be a little while before I can get started on the transom. Thanks, Steven

 

[Bravo]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

Hows it coming along?

 

[Alpheus]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

Deja vu...

http://forums.iboats.com/showthread.php?t=404912

 

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

Hows it coming along?

Things are going pretty slow right now. With summer in hi gear now, the only time I get to work on it is late at night when I am off. Usually from about 9:00pm to about midnight. The kids have something going all the time. I am working this weekend, but I may try and do a little on Sunday night. I am off Monday. I was able to get the consoles supported and the bad wood cut out from under the starboard console. I started on port side, but it is going to take a little more persuading to get the wood cut out from around it. On a good note, the foot rest on the starboard side came apart in individual pieces so I at least I will have a pattern to use when I cut new wood. I found a thread on the Sea Ray 200 on www.clubsearay.com that has some good pics. Thanks, Steven

This is my goal. To get her looking like this one again. I'm jealous:
http://picasaweb.google.com/NCCamper/1992SeaRay200BRSS?feat=directlink#

 

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

Well, it's 1:00am and I just finished the ole super hot/really cold fiberglass removal shower. I made a little progress on the boat tonight after work. I was able to get the bulkheads that support the consoles removed. There were a lot of added screws holding them together. I had to screw a 1x4 as legs to each console to support them and keep them from sagging. Thankfully, the starboard bulkhead was in pretty good shape and I will be able to use the old wood as a pattern. Once I finished with the bulkheads, I removed the engine bellhousing so I could take a look at the actual wood that is between the outdrive and inner mount of the transon. You guessed it, it is rotton. I guess that will be my next task. Removing the outdrive and inner mount so I can cut the transom out. Thanks, Steven

Port side console bulkhead removed:

Starboard side console bulkhead removed:

Both console bulkheads are finally out:

Engine bellhousing removed:

Port side wood of the transom just above exhaust housing between the inside/outside of the transom:

Starboard side wood of the transom just above exhaust housing between the inside/outside of the transom:

 

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

Well, I have been living at work lately and have not had a lot of time to work on the boat. Tonight, I finally found a little time to build my outdrive stand (thanks G1K). All I need now is for it to stop raining (thanks Hurricane Alex). It has been nonstop rain all day. I would much rather have the rain than the wind though. I'll take the good with the bad. Anyway, here are some pics of my outdrive stand that cost less than $25.00 to build. Hopefully I will get it removed and get the transom cut out this month. Thanks, Steven

 

[69rrvert]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

I finally found a little time to get the outdrive removed today although the rain is still falling. The stand that I built works like a charm. Looking at the gimble bearing, it appears to be in need of a new one. I'll probably go ahead and replace the u-joints while it is out as well. Thanks, Steven

Outdrive sitting on stand:

U-joints a little rusty:

Gimble Housing:

Gimble Bearing:

 

[duners88]

Re: '93 Sea Ray 200-BR rebuild (stringers/floor/engine)

The project is looking good. I will keep watching your progress.

I hope your not too flooded or have too many emergency calls with the 8"+ inches of rain you guys got yesterday.

I have friends in West Columbia right on the San Bernard. They sent me picts of the rain and flooding.

-Duane.