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Step
one: Removing decayed plywood decking. Encountered a dozen paper wasp nests and mice....got stung several times.
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What
a mess !...2.5 liter Mercruiser seized from lack of proper winterization. All plywood was rotten, all wiring will
be replaced.
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Under
the decking there are foam floatation blocks. I removed and cleaned them. Note rotted bulkhead (cuddy entry). These
will come out next.
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Cleaning
inside the hull (pressure washer came in handy).
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Note
floor supports (center) I layed marine treated 2x4's along the entire length of each of them making reinstalling
the decking plywood easier. I attached them with stainless screws.
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Disassembling
the cuddy (All wood was replaced here as well).
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The
original helm in need of serious updating/repair.
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While
cleaning the inside of the hull, I filled the boat up with water to the waterline to check for leaky rivets. I
found 6 that were bad, marked and replaced them.
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After
replacing the bad rivets and waiting a couple of days for the hull to dry, I applied Herculiner to the inner hull
to seal any leaks I may have missed.
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Removing
all plywood inside the cuddy (saving the old as a template for cutting the new wood).
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New
wood layed in, preparing to install hinges. I used all stainless hardware to reinstall wood to the aluminum structure.
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Installing
new marine plywood decking. Rivets were used port and starboard, stainless screws used to attach to previously
installed 2X4 structural supports.
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Installing
new trim panels and second section of deck.
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Final
section of deck installed. On to replacing cuddy bulkheads.
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Again
using the old wood as a template, cutting and installing cuddy bulkheads.
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Coming
together nicely. Could not wait to remove the original '60's helm.
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Test
fit of the old cushions before having them reupholstered.
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New
sink cabinet installed (I used mahogany for the countertop).
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On
to replacing rotten transom. First drill out rivets that attach the cowl to the hull, then remove through hull bolts.
(I discarded all old hardware).
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Preparing
the old engine/outdrive for removal.
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Outdrive
removed. Not corrosion holes in transom...more work to do.
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Transom
core plywood removed. Next will be cleaning and cutting out corrosion holes in the aluminum.
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After
carefully removing the old wood, it was used as a template for cutting the new transom. (Two 3/4 sheets "glued
and screwed" together with stainless hardware and 3M Marine 5200
sealer.)
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Rotten
cowl support was used as a template to cut a new mahogany structure. Reinstalling cowl aluminum.
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Cutting
transom repair plate. First I cleaned and cut out the corroded aluminum, applied 3M Marine 5200 sealer and riveted
the new plate in place.
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Cutting
the drive hole using Mercruiser's template. A sawzall is needed here.
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Mercruiser
Alpha One Generation Two drive installation. Installing gimbal/inner transom plate.
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Preparing
to install the engine (2002 Mercruiser 3.0 liter 4 cylinder).
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Lowering
engine into place.
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Installing
exhaust tube and torquing down engine mounts.
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Installing
Mercuiser wiring harness.
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Installing
and wiring trim pump.
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Laying
down new marine carpet, installing helm chair and lounge seat.
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Starting
to look like a boat...
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Getting
ready to build the engine box and stern seating.
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Building
my new helm station and folding cutting board.
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I
installed the lounge seat in such a way that when folded out, contacts the stern seat making an extra bed if needed.
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Mounting
new 18 gallon fuel tank, running fill, vent, and fuel lines.
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Constructing
new helm station. I used corian for the face.
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Installing
steering cables, gauge, and ignition/accessory switch wiring.
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Installing
VHF and antenna wiring.
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Installing
2 12 volt outlets for accessories like spotlights and portable GPS unit. Fire extinguisher installed.
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New
cushions back from being reupholstered, running new bow light and cabin light wiring.
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Testing
electrical system
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Testing
navigation and deck lights.
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Adding
rodholders and bilge blower vents.
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Installing
port and starboard rodholders.
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I
installed rod racks port and starboard for my smaller perch fishing rods using left over mahogany.
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Installing
12 volt marine horn and switch.
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Drive
aligned and installed.
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New
1000 AMP marine battery, bilge and blower hose routing.
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Constructing
engine box/stern filler panels and installing stern seating.
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Finished
engine box and installing rod racks.
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Maiden
voyage ! This is where I discovered the trailer had a severe swaying problem that I had to correct.
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Sink
or swim ? I checked the bilge at the docks after leaving it in the water for awhile. No leaks so far....
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Warming
up the engine at the dock, preparing for voyage to the Bohemia River, Cabin John Creek, Turkey Point, and
back.
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Being
as light as the Chieftain's are, it has a lot of get up and go with just 140 HP. Max speed is 40 MPH.
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Half
way into Cabin John Creek.
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Why
didn't I bring fishing rods ? Turkey Point is off the stern.
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Cruising
up and down the Elk River. Note that I removed the original windshield (top of cabin). I just liked how
it looks with it removed.
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Heading
back to dock after a successful maiden voyage. Crystal Beach is on the left.
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Finally
had good weather so I could paint.
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I
am considering tinting the cuddy windows in the future.
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Painted
transom...now to think of a name for my "new" boat.
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First
fishing trip at Matapeake Kent Island, Maryland.
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First
taking pictures of the new paint job, then on to fishing.
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