I bought a project. On purpose.

PatinIdaho

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Not posted in a few years at least, but i had nothing to post about. Retired now but not rich for sure. Anyway im back now with a 88 Sea Ray 26.8. The plan was to use it for a couple of months, then, when put up for the winter tear into it.
Here is the visible rot.20261008_161715.jpg
 

PatinIdaho

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So Now since last Thursday, when i removed the engine i have been chasing rot wherever it led me. Decided to just drill holes and check the wood.
Turns out both shelves on the left side of the bilge in the pic had wet wood or rot. The transom on the laft side was about half rot near the bottom and dry rot about 1/2 way up and solid wood about 3 inches from the top. Right side the lower shelf was wet dark but solid. The upper shelf has good dry wood so im leaving that alone.20261010_133932.jpg20261012_151049.jpg
 

PatinIdaho

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Seems Sea Ray did not use very good marine ply. The plywood had a lot of knots and for some odd reason they used some kind of putty between the 2 sheets of 3/4 plywood. It's kinda like dry playdough.
There was no fiberglass between the outer skin and inner plywood so they must have used PB to stick the two together.20261013_091526.jpg20261012_152204.jpg20261013_133301.jpg
 

PatinIdaho

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So now i have all the bad wood out except the two engine stringers that im leaving in for now and they are giving support to the. I will be removing them and replacing also. It;s getting to cold out to fiberglass now so ill leave them till the spring, but until then I'll just be collecting up supplies.20261014_115552.jpg20261014_133649.jpg20261013_133239.jpg
 

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PatinIdaho

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The silver tube is pumping in heat from a Diesel heater cuz im old and cold.
Anyway, other than the engine stringers im done removing.
Now i have 20 years repairing Aircraft composites to one dagree or another but a boat requires totally different stuff except resin. I have mostly used Hexion Vinyl ester resin and sometimes Magnolia 6167 epoxy.
I'll be using Vinyl ester resin going back together.
Epoxy might be the best, but im not a fan of working with it myself.
For the transom ill be using 3/4 A or BCX. Not sure yet on what to use for the engine stringers. They are 3 3/4x 2 1/2 x 40 long. Forgot to measure how high they rise for the engine mount but they rise at least 3 inches and it's all cut from 1 solid piece so im not sure what to do there.
I don't need the best as in all reality i'll probably only be able to use this boat for maybe 10 years i would imagine, then it will be the kids problem to fight over.20260821_092154.jpg
 

PatinIdaho

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Forgot to mention. The reason i chose this boat was that 3 years ago the engine was rebuilt and two years ago the outdrive was rebuilt. Both have paperwork to back it up.
I also paid less than it would cost to rebuild the engine.
It is the bad combo though. 454, Alpha 1 gen 1. Im not going to be hammering on it so since it lasted till 2 years ago it should last for me.
 

bakerjw

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Another new member to the team!!!!

1792323766018.png


I love seeing rot removed and replaced.
I wish I had the room to take on more boat projects.
 

PatinIdaho

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You bought a 1988 boat designed to last 12 - 15 years. It lasted 39.

You will most likely be chasing rot all the way to the bow. Check all the foam, bulkheads and stringers
That's true, it lasted 39 years, and that's pretty good!
All the boats i have ever had have had rot. This one i decided to deal with somewhat.
Mostly because i needed a project to keep me busy. I don't want to be that guy who retires and dies. Some guys want cars. I wanted a boat.
Im redoing the bilge area and im not going any further or looking any further. It's no better or worse than any boat i have had. I know ill get some flak for it but that's the way it is.
Most of the wood i have taken out has been damp and dark but still solid. Had to cut it out in chunks as i could not break it out
The worst was on the right upper shelf. About half of it was rotten.
Other than cleaning up the edges and sanding it all im done tearing out for now. Still need to do the engine stringers in a few months.
Oh, and im also re-coring the swim platform
 

Chris1956

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I had a 1988 SeaRay Sorrento. I found the build quality to be inconsistent across the boat. Some parts were made well other parts were made poorly. SeaRay had a quality reputation in 1988, but my boat did not match that reputation IMO.

For example, the plywood deck was glassed with a chop gun. Not unusual, but they seemed to have run out of chopped glass as they went, leaving the transom area treated with just resin. It rotted away, however, there was a skin of glass under it protecting the floatation foam from water. Good stuff.

The center of the Vee hull was supported by a piece of 3/4" scribed plywood, which was supported by the bottom of the ski well. The staples holding the hull support the ski well floor rusted away, the support fell over and the hull deformed. I had to replace the hull support, and the ski well sides and bottom. The top of the ski well had been cut to accept the cover, but the deck plywood edges were not sealed and rotted away.

I suspect the foaming of the hull was incomplete as a strake cracked down the middle. A strake is usually very strong because of the shape of the glass, and the foam support behind it. The crack caused a pretty good leak, and I had to pull the boat or it would have sunk.

The side panels were made of pieces of what looked like scrap wood stapled end-to-end and cut to shape. I needed to replace them with a piece of solid plywood, due to rot.

The boat had a walk-thru windshield. The moveable part of the windshield would fall thru the fixed part of the windshield if I hit a wave with it closed. Obviously, the hull was flexing, gunwales moving out. I expended the lip on the moveable part, and fixed that issue.

Those were the major issues. The wiring, powerplant and fittings were nice, and I did not have any issue with them. I did not have any obvious transom rot, but the doghouse and some of the transom bulkheads needed to be replaced.

Best of luck with your project.
 

PatinIdaho

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I had a 1988 SeaRay Sorrento. I found the build quality to be inconsistent across the boat. Some parts were made well other parts were made poorly. SeaRay had a quality reputation in 1988, but my boat did not match that reputation IMO.

For example, the plywood deck was glassed with a chop gun. Not unusual, but they seemed to have run out of chopped glass as they went, leaving the transom area treated with just resin. It rotted away, however, there was a skin of glass under it protecting the floatation foam from water. Good stuff.

The center of the Vee hull was supported by a piece of 3/4" scribed plywood, which was supported by the bottom of the ski well. The staples holding the hull support the ski well floor rusted away, the support fell over and the hull deformed. I had to replace the hull support, and the ski well sides and bottom. The top of the ski well had been cut to accept the cover, but the deck plywood edges were not sealed and rotted away.

I suspect the foaming of the hull was incomplete as a strake cracked down the middle. A strake is usually very strong because of the shape of the glass, and the foam support behind it. The crack caused a pretty good leak, and I had to pull the boat or it would have sunk.

The side panels were made of pieces of what looked like scrap wood stapled end-to-end and cut to shape. I needed to replace them with a piece of solid plywood, due to rot.

The boat had a walk-thru windshield. The moveable part of the windshield would fall thru the fixed part of the windshield if I hit a wave with it closed. Obviously, the hull was flexing, gunwales moving out. I expended the lip on the moveable part, and fixed that issue.

Those were the major issues. The wiring, powerplant and fittings were nice, and I did not have any issue with them. I did not have any obvious transom rot, but the doghouse and some of the transom bulkheads needed to be replaced.

Best of luck with your project.
Yeah, the quality im finding does not match the reputation but as Scott said. It did last 39 years.
Mine is not flexing. Everything inside feels solid when pushed or pulled or stomped on. I can walk on the forward deck and its solid
Everything lines up as it should and when hitting waves, nothing appears to be flexing or moving inside or on the dash.
Mine in the bilge had what looked like steel staples holding things together and most are rusted away.
There is no way of knowing how many plies to put back. It was done with a chopper gun to about 1/4 thick. Voids are everywhere and it looks like it was never even rolled down after applying.
 

MikeSchinlaub

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Jan 14, 2025
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For those stringers/motor mounts, measure the raised part and get whatever that comes out to in dimensional lumber. Then just rip the stringer part down to proper height.

Epoxy resin doesn't work with csm anyway because it doesn't break down the adhesive used to bind the strands together
 

PatinIdaho

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For those stringers/motor mounts, measure the raised part and get whatever that comes out to in dimensional lumber. Then just rip the stringer part down to proper height.

Epoxy resin doesn't work with csm anyway because it doesn't break down the adhesive used to bind the strands together
Yeah, that was an option using Douglass fir.
And i misspoke earlier. I am very familiar with using Hydrex 33350-15 vinyl ester laminating resin. Not Hexion.
 

PatinIdaho

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One i get this all back together and sanded i wonder if this stuff would work
to fair it all out smooth for the bilge paint?
It is used after a repair on aircraft before paint. I can get two gallons free from work.
SGP16717_1_inset4__33841.jpg
 
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