Project "1600 Capri Hard Top" has begun!

[maxum247]

Re: Project "1600 Capri Hard Top" has begun!

I know what you mean. I've put a lot of time in the gunwales on my boat to get them to the point there at now. When I step back and look at them I feel like what was done should have been finished in a couple of hours not 3 times that. Some parts of a project can just drag!

 

[jcsercsa]

Re: Project "1600 Capri Hard Top" has begun!

I will trade you guys !!! this sanding really stinks !!!! well this isnt to bad , sanding the paint , but that marine tex was really a pain in the you know what !!!! JOhn

 

[Meadfisher]

Re: Project "1600 Capri Hard Top" has begun!

Great job man, lots of work involved in that one. i can realte to never enough time all too well.

 

[drwgblanks]

Re: Project "1600 Capri Hard Top" has begun!

Hey Mark42, it's been a while since I've posted. I am still really interested in your finished project. Do you mind if I ask how much you think you've got invested so far? It's really looking good.

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Hi drwgblanks! Yeah, its been a while. Just checked the project plan, and it looks like just the hard top is up to $600. Most of that is epoxy resin and glass, but it includes things like window channels, lights, hinges and other hardware that you don't see yet.

I put the windshield frames aside and decided to cut out the deck for the extra headroom it will give. I really wanted to do this in pressure treated ply, but I had plenty of CDX, and I couldn't justify buying a whole sheet of pressure treated when I have all this CDX in the garage. Budget cuts.

Some before shots of the deck without the ski locker cover in place. The bilge pump is a new addition. The pencil marks where the deck is to be cut are visible.

check out how much farther the recessed deck will be over the ski locker opening.

Here the deck is cut back to the edge of the stringers, making a 23" wide opening. The bilge pump will be covered.

Here you can see the cut against the stringer. I used a sabre saw, and didn't want to cut into the stringer glass, so the disk sander will smooth the plywood flush with the glass. I got lucky, everywhere I cut is dry as a bone. And the chopper gun or CSM work on these stringers is not too shabby.

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Hi drwgblanks! Yeah, its been a while. Just checked the project plan, and it looks like just the hard top is up to $600. Most of that is epoxy resin and glass, but it includes things like window channels, lights, hinges and other hardware that you don't see yet.

I put the windshield frames aside and decided to cut out the deck for the extra headroom it will give. I really wanted to do this in pressure treated ply, but I had plenty of CDX, and I couldn't justify buying a whole sheet of pressure treated when I have all this CDX in the garage. Budget cuts.

Some before shots of the deck without the ski locker cover in place. The bilge pump is a new addition. The pencil marks where the deck is to be cut are visible.

check out how much farther the recessed deck will be over the ski locker opening.

Here the deck is cut back to the edge of the stringers, making a 23" wide opening. The bilge pump will be covered.

Here you can see the cut against the stringer. I used a sabre saw, and didn't want to cut into the stringer glass, so the disk sander will smooth the plywood flush with the glass. I got lucky, everywhere I cut is dry as a bone. And the chopper gun or CSM work on these stringers is not too shabby.

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Had just enough time to cut some 5/8" CDX for the new deck...

Just need the vertical piece in front of the bilge pump to close the bilge off.

There is about 3 inches of bilge space under the recessed deck. The deck will just lift out. There will be a center rib cut from 1x3 PT (that I already have) to run down the center to give the 5/8" ply some support on its 23" span.

Just have to glass it all over and its ready for the new vinyl deck covering. But that might not happen until later in the summer. I bet the wife will push for the deco dot, she doesn't like the old carpet.

It wasn't as hard as I thought, and it gives me an extra 3 inches headroom. If you are 6', you will just graze the cabin ceiling.

 

[zach103]

Re: Project "1600 Capri Hard Top" has begun!

looking better and better everytime.. keep it up.. why didn't your go all th way to the cabin with the new deck?

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

looking better and better everytime.. keep it up.. why didn't your go all th way to the cabin with the new deck?

That took a while to decide where to stop. I stopped 14" short of the bulkhead so that when standing at the helm, your left foot wouldn't accidentally fall off the edge into the recessed deck and maybe twist an ancle.

 

[Meadfisher]

Re: Project "1600 Capri Hard Top" has begun!

That took a while to decide where to stop. I stopped 14" short of the bulkhead so that when standing at the helm, your left foot wouldn't accidentally fall off the edge into the recessed deck and maybe twist an ancle.

Looks good man, cant wait to it all finished. lol More pics please

 

[redfury]

Re: Project "1600 Capri Hard Top" has begun!

That's a good thought. Of course, you have to remember you are dropping down from that to the lower "aisle" when you leave the seats too

I think it was a good idea. Headroom is always a plus when you have more of it. Are you going to glass the bottom of the wood or just seal it on the bottom side?

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

That's a good thought. Of course, you have to remember you are dropping down from that to the lower "aisle" when you leave the seats too

I think it was a good idea. Headroom is always a plus when you have more of it. Are you going to glass the bottom of the wood or just seal it on the bottom side?

I have the glass and resin, so those pieces will get resin and glass on all sides. I think the recessed deck will be held in place with two screws front and rear so its easy to pull out, and won't rattle around when on the water.

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

I just noticed that the starboard seats are in backwards. You can tell by the gap at the bottom of the seat backs, the port side doesn't have that gap. Good thing I didn't bolt them in place yet!!!

 

[proshadetree]

Re: Project "1600 Capri Hard Top" has begun!

Great work and planing.Picked up a lot of info here

 

[Meadfisher]

Re: Project "1600 Capri Hard Top" has begun!

I just noticed that the starboard seats are in backwards. You can tell by the gap at the bottom of the seat backs, the port side doesn't have that gap. Good thing I didn't bolt them in place yet!!!

LOL, it happens sometimes. Really moving right along, Again man awesome project and great work.

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

LOL, it happens sometimes. Really moving right along, Again man awesome project and great work.

Thanks! I do appreciate the comments.

BTW, as I was pulling wood splinters from my hands, I realized that the edges of the ply were tearing up too much from the circular saw. I had forgot to adjust the blade depth.

When cutting ply, the cross grain cut will not tear up the top layer much at all if the blade is set to just clear the thickness of the ply. IE with an 8" blade, you don't want 2" of blade showing below the ply, only 1/4 -1/2". Makes for much smoother and less splintery cuts.

 

[bear_69cuda]

Re: Project "1600 Capri Hard Top" has begun!

Hi Mark,

Great idea with the recessed deck, room in boats is a premium for sure! I always enjoy checking out your project, and watching how your brain works! Wish I lived closer. I'd love to lend a hand, or just kick back shoot the breeze and have a beer! Again my friend, looking killer! Stringers do look solid!

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Hi Mark,

Great idea with the recessed deck, room in boats is a premium for sure! I always enjoy checking out your project, and watching how your brain works! Wish I lived closer. I'd love to lend a hand, or just kick back shoot the breeze and have a beer! Again my friend, looking killer! Stringers do look solid!

Thanks Bear!

Ya know who else is doing an interesting remodel job on a Bayliner 1600 bow rider is DORELSE. Has it on the baylinerownersclub.org site under finished projects, but its still not finished. Wish he would post it here more often. He's changing the seat layout, putting in a bench seat and a sun deck.

 

[bear_69cuda]

Re: Project "1600 Capri Hard Top" has begun!

I so wanted to change my layout as well... Captains chairs, and bench seat with sundeck! But I just couldn't justify it... Maybe if in a few year's I decide not to trade up to a different boat, a 4.3 L and that combo would rock in "SS Hurry Up" !

 

[Mark42]

Re: Project "1600 Capri Hard Top" has begun!

Here's today's progress....

Got all the deck pieces glassed on the top side, and two coats of resin on the bottom and sides.

When the recessed deck section was in the boat and walked on, it was flexing. Guess 23" wide span is too much for 5/8" ply. So I added another layer of 5/8" to the bottom, just about 2" smaller all around. Used waterproof carpenters wood glue, and utility screws to hold them tight until the glue set. Then the screws were remove, the the bottom coated with resin. The top side screw holes were filled with bondo before glassing over.

Final fitting. Everything was sanded smooth so when the Nautolex vinyl is installed later, it won't be full of bumps. Little 2x2 pressure treated blocks were epoxied to the under side of the old deck for the new end pieces to screw to.

The bilge pump cover has two cleats on the bottom so it won't slide around and will stay secure in place.

I was hoping to get the top off the boat and put the boat in the garage, but maybe I can do that tomorrow. The motor has to be moved to install the ram end of the new steering cable. There is a come-along hanging from the ceiling of the garage that will make that job easier.