Starcraft 1978 16' SS Restoration - Multi-year Project

[tlynch99]

Re: Starcraft 1978 16' SS Restoration - Multi-year Project

At this point in the project the boat interior was cleaned out, I had cut all of the new foam I was going to put back in, and it was time to start templating the deck. I used a hot glue gun and some scrap pieces of cardboard to make the template of the bow section. The middle / stern sections I was able to just measure and rough cut the plywood. I decided to go with 3/4 decking.

Here is a picture after 1 coat, the smaller U shaped piece is for the bilge area:

I used an extra piece of plywood as a support while I walked around in the boat. I have one more section of foam for each side that was put in under the decking, that isn't show in this picture:

Bilge area foam cut:

Another picture:

Bow area:

continued....

 

[tlynch99]

Re: Starcraft 1978 16' SS Restoration - Multi-year Project

Laying the pieces in:

It sure was nice to stand of the firm deck after having such a soft one.

I decided to rivet the deck down, After making some chalk lines for where the stringers where I drilled each hole, put some epoxy in the hole and riveted the deck to the stringers.

Un-fortunately I can't find any pictures from when I did the carpeting. I used a marine carpet I bought from overtons, and a carpet adhesive they sold.

Picture with carpet, and testing where seats will go:

 

[tlynch99]

Re: Starcraft 1978 16' SS Restoration - Multi-year Project

In this picture you can see I screwed around with colors in the spashwell, this is a rustoleum color.

Boat paint job:

As you can see from some of the pictures it's spring in New England (2009) and at the very end of the 08 season I noticed a clicking sound coming from my lower unit while underway. I purchased a similar one off craigslist that was know to be working. All of my research was pointing to a problem with the clutch dog or the teeth being worn. Anyway I knew I wanted to change the water pump as well.

Troublesome lower unit:

Lower unit removed, it actually wasn't as bad as I thought it was going to be:

There was a bunch of white stuff that came out when I took the bolts off, a quick taste told me the motor had been used in salt water.

 

[tlynch99]

Re: Starcraft 1978 16' SS Restoration - Multi-year Project

Old, on the left, and new to me lower unit on the right:

Taking stuff apart:

I learned a good trick to help get the water pump impeller back in, while trying to push the housing back down over the impeller, if you put a little bit of grease on the impeller it will go back on much easier, and then the grease will wash out when the motor is run.

Putting the lower unit back on was not too bad either, the biggest issue I had was getting the linkage of the shift lever aligned and the bolt through the hole.

 

[tlynch99]

Re: Starcraft 1978 16' SS Restoration - Multi-year Project

Still being spring time, I decided after the job of replacing the water pump went so well, I would replace the head. Fixing the spark plug helicoil problem I had.

Removed all the bolts and the old head came right off.

Old head picture:

Powerhead with head removed:

Picture of piston, I had used seafoam the season before to de-carb the motor and it looked fairly clean inside.

 

[tlynch99]

Re: Starcraft 1978 16' SS Restoration - Multi-year Project

One thing I was amazed at was the lack of scoring on any of the cylinder walls, for a motor being a 1978 if this is the original powerhead it looked pretty good to me:

New head, I followed the procedure in the evinrude manual to slightly resurface the head as I didn't know anything about this new head (bought off ebay $20):

New head installed:

After installing the new head, I no longer had any issues with the spark plugs.

One problem I did have when trying to de-winterize and start the motor for the first time was with the starter. After buying a new one from iBoats I was ready for the 2009 boating season.

Other pictures of the interior going back in, coming soon......