New Project Boat Rebuild

Discussion in 'Boatbuilding' started by Ike, Dec 27, 2011.

  1. Ike
    Joined: Apr 2006
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    Location: Washington

    Ike Senior Member

    Good advice. That's probably what I will do. I have already mounted a small outboard kicker on the boat.

    I figure I'll run it til it dies and then yank it out and replace it.

    Years ago I had a car engine that I had rebuilt. I did the block. I had a pro do the head, (it was an overhead cam) Put it back together. Ran great, everything checked out. Drove it another 60K miles ( 2 trips across the country in there) and it blew the head gasket in New York City. I really don't want to go through that again. (of course it could have something to do with the fact that it was a sports car and I drove it hard all the time. )
     
  2. ub3r l33t dud3
    Joined: Sep 2012
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    Location: capac michigan

    ub3r l33t dud3 Junior Member

    nice boat! i grew up on one of these, in fact we still have it. a word of cation about the exhaust manifold, ours rusted out on the inside without us knowing it and when we went to start it up water had back-filled one of the pistons and bent the connecting rod. best of luck though with the boat! i still love ours :)

    [​IMG]
     
  3. Bomlo
    Joined: Sep 2012
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    Location: UK

    Bomlo Junior Member

    Any fiber glass work has to be done in this boat??if not please recommended to you to do work fiber glass.
     
  4. PAR
    Joined: Nov 2003
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    Location: Eustis, FL

    PAR Yacht Designer/Builder

    Bomlo . . . what are you attempting to say?
     
  5. Ike
    Joined: Apr 2006
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    Location: Washington

    Ike Senior Member

    Sorry about the long delay. Due to other financial issues and internet problems I have done very little. I did order the new thermostat housing (upper and lower) and yesterday ordered a new exhaust manifold and all the other stuff that goes with it.

    Meanwhile I pulled the lower unit of the stern drive and replaced the impeller, gaskets, housing, etc. But try as I might, that sucker would not go back on. It would stop with about a half inch gap. I tried everything, rechecked everything, drove me crazy. So I took it to Commencement Bay Marine and in about fifteen minutes they had it back on. I should have had them do it when they did the upper unit. Live and learn.

    But I am now up against a deadline. I have To get the boat out of this RV park by November. So I have to find a place to keep it. I have some options. So it's not too big a problem. But it has to be someplace I can work on it.
     
  6. PAR
    Joined: Nov 2003
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    Location: Eustis, FL

    PAR Yacht Designer/Builder

    I have space in my yard. Rent free if you bring beer on Saturdays.
     
  7. LP
    Joined: Jul 2005
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    Location: 26 36.9 N, 82 07.3 W

    LP Flying Boatman

    Is this invitation only for Ike or is it to the whole classroom? :p:p:p
     
  8. Ike
    Joined: Apr 2006
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    Location: Washington

    Ike Senior Member

    Thanks Par. If you weren't 3000 miles away I would take you up on that! But I found a place today. So problem solved. This afternoon I have to go pick up the new exhaust manifold and other exhaust parts at the UPS center. So I should be able to get back to work.

    By the way, hallelujah! its's raining here. That may sound strange but it's been 80 days, an all time record, without any significant rain. We had one day when there was some rain but it was barely measurable, So this is cause for celebration. We really need the rain. There are many forest and brush fires burning and we need the rain to put them out. All the grass has gone brown which almost never happens here. We also need it to fill up the reservoirs and lakes. The lake I am on is down about 1 1/2 feet. Lower than I have ever seen before.
     
  9. PAR
    Joined: Nov 2003
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    Location: Eustis, FL

    PAR Yacht Designer/Builder

    It's a fairly open invitation, but you'll need at least two six packs, per Saturday Greg . . . :)
     
  10. LP
    Joined: Jul 2005
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    Location: 26 36.9 N, 82 07.3 W

    LP Flying Boatman

    Did you want me to bring some for you too?:p
     
  11. PAR
    Joined: Nov 2003
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    Location: Eustis, FL

    PAR Yacht Designer/Builder

    Only if you feel the need Greg . . . free beer is terribly hard to turn down, especially after the first couple.
     
  12. Ike
    Joined: Apr 2006
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    Location: Washington

    Ike Senior Member

    Finally getting things done. See pic below of new manifold, water pump (behind the pulley) thermostat housing and hoses.

    [​IMG]

    However, as usual I hit a snag. In the pic below, notice that the bolt immediately to the right of the last bolt on the manifold, is missing.

    [​IMG]

    I cleaned everything up. put the new manifold and gasket on, started tightening bolts (alternately, first one end then the other, the the middle two, and so on) and when I got to that one, which was the last to be tightened, it would only tighten so far and then it slipped!. I nearly threw in the towel. Possible stripped threads in the block, and other thoughts (not printable) went through my head. Then I took the washer off and tried it again, and this time it tightened up, but with the washer it's too short. So I looked at various alternatives. Yes I tried chasing the threads with a tap. Didn't work.

    Get a longer bolt?
    Put in a stud?

    In the next pic the original bolt is on the right, and it's hard to see but only about 1/4 to 3/8 inch was actually in the hole, which is a good inch deep. So getting a longer bolt might work. The new bolt was exactly the same length and just wasn't grabbing enough threads.

    So I took one of the old studs and screwed it in and it holds but the threads aren't very deep, so I bought a new stud with deeper threads (last one on the left.) This will go all the way into the hole and have plenty of thread engaged. I can then put a washer and nut on it, and cut off any excess, so it isn't sticking out there to cut me every time I work on the engine.

    [​IMG]

    I went to Tacoma Marine , the local mercury parts and repair, and showed their head mechanic what I was going to do. He thought it would work fine.

    So next, I have another hose to put on, the exhaust shutter, the exhaust hose, and the riser. Then install the carb and the throttle linkage and I should be done. (this time anyway)
     
  13. Ike
    Joined: Apr 2006
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    Location: Washington

    Ike Senior Member

    Done done done. New Water pump, new thermostat and thermostat housing, manifold, water hoses, exhaust hose, and water shutter. All bolts, nuts and washers are new SS. I used the existing riser. It looks like crap on the outside but the inside looks fine. I'll change it out in the spring. Now I need to put it on the earmuffs and run the engine.

    [​IMG]

    Those of you with sharp eyes will notice that the throttle is not hooked up to the carb yet. I did that later.
     
  14. PAR
    Joined: Nov 2003
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    Location: Eustis, FL

    PAR Yacht Designer/Builder

    A can of aerosol engine paint wouldn't hurt either . . .
     

  15. Ike
    Joined: Apr 2006
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    Location: Washington

    Ike Senior Member

    Geez, always a critic. LOL
     
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