Extreme makeover 72 seafari 25 aloha edition

[Xcomunic8d]

so here's some more stuff:

after I completed this part of it, I went more after the engine. I was concerned about it's state and what we would have to do if I couldn't get it running. Long story short I never want to tear a 20 yr old saltwater outboard apart again...

ps: here's some of my treasures after surgery. my stones were 10-12mm I had several in each kidney. one surgery the dr said when I hit it with a laser it exploded and you have shrapnel everywhere in there that you will have to pass.





yes, this is a bent flywheel on a 96 Suzuki dt200. got it off and have a new one for it, now.






so here's the massive outboard teardown. got a new lower unit, new seals, new wristpins, cylinder rings, cir clips, injectors, gaskets, and more. just about a total tear down and complete rebuild

[uncleboo]

Sorry you had such a rough time! Glad to see you working on the boat again.

[cdavisdb]

And I thought mine was a lot of work! Hats off to you for sticking with a big job! Looking forward to seeing some pics of your first trip offshore.

[Xcomunic8d]

I’ll try to add some pics later...

Between the aft bulkhead and mid bulkhead, there was a large amount of float foam under the fuel tanks.

I’m doubting this was factory. There was no seeming way for water to drain to any bilge pumps. This soaked foam and water were held up against the wooden bulkheads and caused them to rot.

I’ve removed this foam and am replacing the bulkheads. Positive buoyancy makes sense to me. But not having proper drainage makes no sense. So advise me please

1. Would you suggest installing drain tubes fore to aft and float foam around them
Or
2. leave area open and put pool noodles and a bilge pump or two in there?

Bulkheads will be made out of thermolite (like coosa board).

Ty and hope all had a happy and safe 4th!

[Capt Chuck]

Leave the bilge open to breathe. No foam and for godsakes No Pool Noodles. They would rot before you brushed your teeth the next morning. Where in the hell did you get that idea? Spidercrab? Why do you think Potter had vents in all models for over 12 years........
Keep the moisture out
Think about it !

[cdavisdb]

Sounds like mine, foam under the fuel tanks and cabin, poor drainage. Same issue with the bulkheads, foam + water + wood bulkheads = ROT, I hate foam. My foam was factory. At least forward, it looked like Potter tried to replace the lateral reinforcement that Moesley would have had to include, with foam. Seemed to work ok on many boats; mine took the best part of 40 years to fail.

I removed all the foam in the process of replacing bulkheads(with holes for air circulation) and added a couple of full height bulkheads under the cabin and some low ones under the fuel tanks. Much stronger now and didn't add much net weight.

If you decide to not replace the foam, be sure and add some reinforcing bulkheads and extend the forward stringers to the forwardmost bulkhead. Be careful of making hard spots; don't ask me how I know this.

[Xcomunic8d]

got the pool noodles idea from here:

http://www.classicseacraft.com/commu...t=pool+noodles

I wanted to get flotation and drainage...

ty cdavis:
I'll have to think through what to do here on this one. Adding bulkheads and lateral support makes sense if the foam is gone. Getting it out from under the cabin is going to be a real pain.

I'd like the extra floatation as i'm going way out there. my side of the island has 4-8ft all the time. the leeward side is like bath water.

I have plans to cross the Alenuiha'ha channel (or I'll-end-you-ha-ha channel), it means roughly strong winds crashing in Hawaiian. the boat did that in the past and I hope to keep it going in the future.

[cdavisdb]

If the foam under the cabin is intact, not cracked and getting shifted out of place, you are probably fine. I'd watch it though. Look for stress cracks in the chines below the foam and near where the bulkheads are.

There are some real good threads(with lots of pics) about working in this boat, mine, Strick's and Blue_heron particularly. Cut a hole in the deck in the cabin and there is room to work under the deck(helps to be skinny as me). The search function should bring'em up.

[Xcomunic8d]

So I finally got the aft bulkhead templated and began filleting in.
https://ibb.co/wsk2qZv

I’ve removed the bulkhead under the cockpit severe rotting again... bottom third was just gone. Mush

https://ibb.co/9r9rymS

After the bulkhead came out, was able to remove foam easily. Forward bulkhead is rotted clear through too.
https://ibb.co/QYr2jNg

I’ll need to sort out drainage soon. Fore to aft. Planning to install bilge in forward area. Will Extend stringers as suggested, and lay down some fresh glass and gelcoat. And add some cross braces that will support tanks and tie the sides together.

[cdavisdb]

How long had that boat been sitting?

Try to use it with bulkheads like that and it should have shimmied like a hula dancer.