seven_magnum's 76 Starcraft Islander 221 rebuild

[dozerII]

Re: Well, I did it!

Re: Well, I did it!

Boy you showed them, way to go great progress.
Glen

 

[seven_magnum]

Re: Well, I did it!

Re: Well, I did it!

Well, I didn't do much on her today but I did take the cam out of the motor and the rest of the lifters. (4 were pretty stuck and I had trouble getting at them from the top.)

These straight sixes are a little different from a v8. On my 350's, i can just grab the cam and pull it out once the chain is out of the way. The cam on this 250 has a thrust plate under the timing gear. There are two access holes that you must align with two screws inside to loosen this plate. Once they are out, the cam pulls right out.

Everything looked pretty good in there. I didn't see any copper on the cam and the cam bearings look pretty good. Either way, they will be replaced though. I hope to drop the block off at a shop this weekend to get the work started.

I guess the manifold was the cause of this rust? I better get one of those on order as well!

If there is anything in particular about the rebuild of this motor you want info on or pictures of let me know. I will be taking pictures every step of the way!

Foster

 

[CheapboatKev]

Re: Well, I did it!

Re: Well, I did it!

The manifold COULD be the issue, is it crazy rusted inside? can you chip off huge chunks with a screwdriver?
If it is suspect at all, and with a new rebuild you really dont want to risk your motor due to a 200.00 manifold. Get a new one.
It could also be that part of a shutter you posted earlier I commented on allowed water to be sucked into the motor, it waterlocked p and sat, rusting away waiting for you to save her..

Or not..lol

 

[GA_Boater]

Re: Well, I did it!

Re: Well, I did it!

I think this one will be saved unless the shop has bad news about the block.

 

[seven_magnum]

Re: Well, I did it!

Re: Well, I did it!

I have a good feeling about the block on this one. The motor didn't see too much use, as the bores are still factory sizes. I thing a .020 or .030 bore at the worst should clean it right up. If it wants to be really stubborn, I will have #5 sleeved but I doubt that will be the case. I looked it over pretty hard and don't see any signs of cracks. The cooling passages have some rust though. The rear most passages into the head are the worst. I can chip pieces off with a screwdriver here. I will have it cleaned up and hot tanked to get rid of that stuff hopefully.

A new manifold will be purchased for this engine. One thing I am kicking around is to change it to a closed cooling system. This boat will see brackish and salt water occasionally. I will run it on muffs when I pull it out of the water and then spend an afternoon or so on the river to make sure it is flushed out. I just don't want this thing to rust like it is now. I haven't shopped around for the kit yet, but most of what I saw was around $700. It kind of made me wonder if I could piece one together for cheaper, but then I would be up a creek with the manifold issue.

The manifold is pretty rusty, but not flaking rust. I'm at a loss with it but I don't want to take that gamble either.

I thank you for your help!

Foster

 

[CheapboatKev]

Re: Well, I did it!

Re: Well, I did it!

Honestly, I dont think a CC system is worth it.
If you flush religously after each salt water use and a little salt away type product would keep you clean.
Glad to hear you are changing the manifold, thats the right way to go

 

[wappycat696]

Re: Well, I did it!

Re: Well, I did it!

I have a good feeling about the block on this one. The motor didn't see too much use, as the bores are still factory sizes. I thing a .020 or .030 bore at the worst should clean it right up. If it wants to be really stubborn, I will have #5 sleeved but I doubt that will be the case. I looked it over pretty hard and don't see any signs of cracks. The cooling passages have some rust though. The rear most passages into the head are the worst. I can chip pieces off with a screwdriver here. I will have it cleaned up and hot tanked to get rid of that stuff hopefully.

A new manifold will be purchased for this engine. One thing I am kicking around is to change it to a closed cooling system. This boat will see brackish and salt water occasionally. I will run it on muffs when I pull it out of the water and then spend an afternoon or so on the river to make sure it is flushed out. I just don't want this thing to rust like it is now. I haven't shopped around for the kit yet, but most of what I saw was around $700. It kind of made me wonder if I could piece one together for cheaper, but then I would be up a creek with the manifold issue.

The manifold is pretty rusty, but not flaking rust. I'm at a loss with it but I don't want to take that gamble either.

I thank you for your help!

Foster

Foster,
I can't believe it! I was searching around for info on Islanders and stumbled onto to your thread. I thought the boat looked familiar. I almost snatched it up just before you but I chickened out at the last minute. It was super windy that day and when I looked it over, the engine and the interior scared me, the trailer looked rough and I just backed out. About half way home I was kicking myself. I called the guy about three days later for a second chance and he said a guy was coming from PA to look at it and I could still have it if he didn't want it . And of course, you did buy it. I was so upset. But I did find another Islander near Chicago and I snatched it. So excited!! I have it tarped until spring due to the fact that I don't have a warm building to work on it. Good luck on everything. I'll be watching your thread. I'm glad she's getting a new lease on life. Rick

 

[seven_magnum]

Re: Well, I did it!

Re: Well, I did it!

Hey Rick,
Small world huh? It was me for sure! When we were about to drive home with the boat Jym told me anther man had looked at it but didn't want it. He said later he had a call back from the man saying he wanted another look at it if I did not buy it! Honestly, I only bought the boat because of the shape of the hull. He told me on the phone that the hull was in great shape, but everything inside was shot. He wasn't lying. Just about every piece of wood I tore out of the thing was rotted, but my father is a carpenter so we will get it pieced back together.

The trailer? I don't know where to start with that one. I can't belive I didn't have any trouble bringing it home. :facepalm: I did bring 2 new wheels with me and changed them before we left because I was told they had some dry rot. I greased the bearings as well but I was still nervous with as far as I had to drag it. I put some magnetic lights on the trailer and only had to stop 3 times to fill up with gas!

I stumbled across this site searching for Islanders as well and everyone here seems quite knowledgeable! I am learning every step of the way on this one but I hope to get her put back together before too long.

My boat is tarped up right now waiting for me to feel motivated enough to pull the transom. Its so far gone I don't know how much I will be able to save for a template. Oh well, one small step at a time.

I am dropping the block off at the machine shop on Wednesday so we will see what they have to say about it. I have a 350 block sitting next to it right now and I hate to tell you about the little idea I had if this 250 wouldn't work out!

How was the islander you pick up? Post questions on this site if you run into any. Everyone here has happy to help out. Thank you everyone!

 

[barato2]

Re: Well, I did it!

Re: Well, I did it!

Hey Rick, welcome to the insanity. open a thread on your boat, eh? i loves me them old cruisers!

 

[seven_magnum]

Re: Well, I did it!

Re: Well, I did it!

Tonight I finally got time to pull the valves out of the head and get everything ready for the machine shop. I am dropping this bad boy off after work tomorrow! I am excited to see what they have to say about the block. I have been cleaning the cylinders a little bit and they look to be in decent shape!

I also cleared another hurtle today. I had some trouble getting paperwork for the trailer. It was sold to me without registration or a title. (Neither is required for a sale in Ohio) I had no trouble with the boat. I had a title in hand for that in about a week. I finally have everything settled with the trailer and I should have paperwork for it in about 10 days!

Next on the plate will be a new piece of wood that supports the cabin windows in the front. Mine is rotted out from the windows leaking and that makes the front of the boat a little soft. Then, this cracked rib up front. I have an idea about fixing it I think will work pretty well. (I will make a video of how this will be done.)

Then the transom. I can't wait until that is out. And the leaky rivets fixed. And gluv-it. And paint....

Foster

 

[seven_magnum]

Re: Well, I did it!

Re: Well, I did it!

Oh man, I have a problem.
This morning I through the block in the back of the truck to drop off at the machine shop after work. As soon as I got the block in the truck and in the sun, I saw it. A crack half way down the #5 cylinder. :facepalm:

I don't know if it's the whole way through, but I can see a .060 bore will not clean it out.

Plan B?

Reman long block with a 7 year warranty. I found a few sites that had them for $1,259.00

I guess I will stop by the machine shop and see what they have to say, but I think this will be cheaper than fixing the block at this point in time.

Foster

 

[dozerII]

Re: Well, I did it!

Re: Well, I did it!

Boy does that ever suck Seven, there never seems to be a "full" when it comes to filling the hole a boat makes in the water with money.
Glen

 

[GA_Boater]

Re: Well, I did it!

Re: Well, I did it!

Oh . Since you were planning on a rebuild any way, maybe you can find a good block and do the rebuild. It wouldn't have a 7 year warranty but cost wise it has to be cheaper. Sorry Seven.

 

[ezmobee]

Re: Well, I did it!

Re: Well, I did it!

I/O, I/O so it's off to work you go..........

 

[barato2]

Re: Well, I did it!

Re: Well, I did it!

or was that I/O, i owe.....

FWIW, i don't think there's anything special about the block in the "marine" engine....all the marine conversion stuff gets bolted onto the same hunk of cast iron. can't be that hard or costly to find a 250 Chevy six.

sorry to hear. about how i felt when i took the cyl head off and found what looked like menudo cooking in #3.....

 

[seven_magnum]

Re: Well, I did it!

Re: Well, I did it!

Well, my progress has been a little slow recently due to work during the week and snowboarding during the weekend. But now I am ready to buck rivets!

I am thinking of buying a set such as this, as I have nothing for solid rivets at the moment.
http://www.ebay.com/itm/Rivet-Gun-K...345?pt=LH_DefaultDomain_0&hash=item3f1397be11

I would use them with aluminum rivets probably from McMaster Carr.

Is this what I need? I want to go with rivets and not screws, as I have all kinds of jobs these could be used for.

I thank you for your help! I'm trying to get my ducks in a row before I go to Japan for work.

Foster

 

[seven_magnum]

Re: Well, I did it!

Re: Well, I did it!

I made some progress today. I ordered a rivet gun, bucking bar and some rivets. Then I went out and stated on the boat. I took out the rotted part under the windshield and then took out the transom! It was a total loss. I pulled it out in 2 big hunks, and 5 gallons of pieces. I took some pictures, but I don't have the camera with me at the moment.

To get the transom out, I took off the railing around the back of the boat. I took out the screws that went through the transom from the outside of the boat. I then took the corners off the rub rail and took the back rub rail out. I then took the screws out of the metal rub rail housing and pulled it off the boat. Then I took the rub rail off the sides. I had to pull the front cap from the boat and drill out the rivets that held the rub rail in place. Then I could slide the sides out.

I loosened the rub rail housing at the transom where it was holding the metal in place preventing the transom from coming out. Then I drilled out the rivets that hold the piece of metal over the transom and took it off the boat. The tabs from the gunwhale that were over the transom bent out of the way easily. I will have to problems putting the new one in!

Now my next step is fixing rivets, and fixing that cracked rib in the front of the boat. I am going to start cutting out panels for the boat, but im not going to install them until i have the gluvit finished.

Sorry for the typing. Im using a really, really little laptop to do this and the keyboard and my fingers arn't getting along. It's painful!

I will upload pictures when Im back behind my machine.

Foster

 

[GA_Boater]

Re: Well, I did it!

Re: Well, I did it!

Sounds like your making good progress, Foster. I know exactly what you mean about using the laptop. Doing the same thing right now too. Yuck!

What's happening with the motor? Any news from the shop?

 

[seven_magnum]

Re: Well, I did it!

Re: Well, I did it!

Ha, I have a plan for a motor all right! The old one is still sitting in pieces in the shop, and the new one is on the way! I bought a long block to through into it. Once I have this thing watertight and painted up pretty, were putting the heart back in! Until then, I have to look at my transom assembly and see what I can do there. I want to replace the gimbal bearing and bellows while it is out, and there was a little bit of slop side to side in the bell housing for the outdrive. I need to see what is going on there and fix what is needed!

Foster

 

[seven_magnum]

Re: Well, I did it!

Re: Well, I did it!

Here are the pictures of the job. Tomorrow I am going to fab up the new board to support the bow and the board in front of the transom. I plan to install it the following day. My trip to Japan is postponed to next Wednesday so I still have time.

Oh yeah, and my bucking bar arrived today! I can't wait to start painting this beast!