Rehabbing my 1988 pilothouse

[ThePrivateer]

I bought my boat back in December an have been dying to start a major rebuild. Just waiting for the weather to break.

 

[ThePrivateer]

So one of the main projects I have planned is replacing the fuel tank and the deck.
It’s a shame to disturb the deck because it’s solid as a rock, but I will feel better knowing what’s going on under it.
I will be replacing the entire deck with 1” Coosa board. (3 sheets already ordered)
Some of the other projects will be:
Replacing the dated electronics with newer but not brand new raymarine radar/chart plotter. (C-80 in excellent condition).
New spotlight.
Installing a 120v panel to power a new battery charger and a few outlets.
New smart plug shore power inlet.
New led navigation lights.
New led cabin lights.
Bottom paint.
New decals, already purchased.
Msa toilet.
Install porthole windows in cabin.
Taco grand slam outrigger bases with 15’ poles.
Custom fabric covers for outboard cowling.
Deck hatches.
Building a removable splash well to hide engine rigging and for storage.
Replacing teak cabin door with the newer style white door. Either purchase if I can find one or fabricate one.
Custom consoles inside cabin to house wiring, battery charger, 120v panel etc.
Would love to install a second station in the cockpit, (side mount type) if I can find one. Any leads would be appreciated !!
Lots of re-wiring.
And much more.
That’s my wish list. Most of the parts and accessories already purchased over the winter.
But I’m sure I’ll find other things that need addressing.

 

[ThePrivateer]

Removing the deck was easy. But getting the tank to budge was a real pain. I ended up removing the rear bulkhead between the tank and the battery compartment si I could start digging the foam out which was completely saturated with fuel co I could get some kind of gripping point on the tank.

 

[ThePrivateer]

The tank is completely foamed in and will not budge. I used a hand saw to cut the foam along the sides of the tank and stringers and still won’t budge. So I came up with another plan, and it worked perfectly.

 

[ThePrivateer]

The back bulkhead is a mess!!!!

 

[ThePrivateer]

A real mess!!

 

[ThePrivateer]

I used a cherry picker and a strap with a hook and pulled it right out!!

 

[ThePrivateer]

A little maneuvering and it is out!!!

 

[ThePrivateer]

The bottom of the tank was in pretty bad shape, found some sizable holes. 2 of them were about 1/8”.
I had previously pumped out about 50 gallons of fuel and am surprised there wasn’t more fuel in the bilge. Must have been semi corked by th foam.

 

[ThePrivateer]

Tank removed, time to remove the fuel saturated foam.

 

[ThePrivateer]

And when I said saturated I meant saturated. The bags of foam weighed more than the tank.

 

[ThePrivateer]

All cleaned out, time to get a new tank fabricated!

 

[mheltunen]

Nice work! Please keep the pictures and posts coming. I love following these older rehab projects.
My 2320 is a 1994 and I suspect I’ll be doing the same thing in a couple years. Do you plan on replacing the tank with the same style? I’ve considered installing two tanks when I do it. Mine is very heavy in the back and would prefer to keep more weight forward when I don’t need a full load of fuel.

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[ThePrivateer]

I could use some suggestions on glassing in my floor, I acquired a nice quantity of west marine 1 1/2 oz fiberglass mat and west system 105 epoxy and hardener. Would this be sufficient for my deck?

 

[ThePrivateer]

Thanks. Yes I plan on installing the same type of tank. I am considering extending back into the battery compartment by about 2 feet to give me more fuel capacity. Not sure about that yet or if it’s really worth the extra money

 

[mheltunen]

I could use some suggestions on glassing in my floor, I acquired a nice quantity of west marine 1 1/2 oz fiberglass mat and west system 105 epoxy and hardener. Would this be sufficient for my deck?

I’m not a fiberglass expert but I’m sure some of the other members may have some suggestions.


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[MadGar]

Thanks for posting this, I will enjoy following you.

I’m sure there will be some members coming by with suggestions however, if you need some advice, I also frequent the Bateau website and there is a section on rebuilds. A lot of advice for free from knowledgeable individuals.

Try
https://forums.bateau2.com/viewforum.php?f=10

You will have to create an account but post what you’ve done and they will share all the information you need on fiberglass and epoxy. Much like this site but more towards building boats and using epoxy instead of polyester resin. Great tool

Best of luck and please keep sharing here on classicparker

 

[Brent]

Look at using a scarf joint

https://www.amazon.com/WEST-SYSTEM-875- ... B003E1WK46


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[GoodChance]

To reattach the plywood cover that you removed last week, first you'll need some sort of "ledge" placed on/along the original stringers for the plywood to lay flush with the existing deck. You can use 5200 or an epoxy bonding agent between the plywood floor and the ledge-stringer. Then grind down a 8" wide swath on the perimeter of the cut (4" on the cut plywood and 4" on the existing floor). Get some 6" and 8" wide 1700. Lay 2 layers of 1700 along the cut and saturate each layer with epoxy resin. You can put the 6" layer first, and the 8" layer immediately after without delay between the two. Let dry. Lightly grind the high spots. Start fairing with any epoxy compound.

 

[ThePrivateer]

Just got my new engine cowl covers !!
Had them made locally and had vents sewn into them so I don’t have to remove them while running. Really made my engines look a lot better.