Putting the Cap back on

It is update time again. It has been tough to find time to work on the boat alot the past couple of weeks, much less update the thread and website. Things are really coming together, and I can see the light at the end of the tunnel.

I am going to change the thread format a little and type what I am doing above the pictures to help dictate what is going on better. As I mentioned before, I will most likely be doing gel coat all inside the boat and then using hydroturf glued in as mats. I think this is the best of both worlds and will give the new owner a slick updated look, and if they choose to put down carpet... they can. More to come on this.

So here we go.

We needed to get the gas tank structure built... so Dad and I rigged up a nice system to raise and lower the cap so we could check fitment. I just used a 1/2 ton hoist screwed into the joint and it allowed me to raise and lower with ease.





We used the cleats to tie the rope to.



I then assembled the old tank structure (see why I kept it) and put it back in to make sure it still fit... which it did.



I then tore it back down again and then traced all the patterns on the new wood and cut it out.



One I had all the pieces cut I had to glue the 2X3 pieces of wood down to the deck that form the structures base. I used Peanut butter (thickened resin) to do this and then used some weight to hold it down. These will also get glassed later.





After treated the end grains with several coats of slow kick resin (resin mixed to cure slowly so it soaks in) I used Peanut butter again to glue and screw the sides to the bases. I used 1708 on the outside and the inside of the base to really hold it to the deck.



Once that cured I put down teh gas tank floor that had been coated in resin and one layers of CSM. I like using CSM on boards that will be sitting flat. The CSM really adds that extra water protection. Boards that are not structural, and are vertical, I usually just tab in and then coat in resin and then paint of gel. The water will run right off this. 

I glues and screwed the floor in also and then tabbed with 1708.



Once teh resin cured I rolled on two coats of rustoleum grey to give the structure and nice look.







I also cut out the transom hole with a Dremel tool. I still need to drill the steering relief holes, but I will do that soon.



I have alos started working on the wiring for the boat. I know it looks like a mess, but I know what is going on. The wiring is actually very usable, and will cut down on time. I fellow boater and fan has graciously made me a great deal on some gauges for the boat!



I also discovered that the Steering is shot, and I will have to get a full new rack. Soooo the steering got ripped out.



I was happy to find out that the instrument cluster can be buffed to a shine. It is that clean circle on the left. One of the videos shows it better.



With a new fuel sender installed, the gas tank is back in her resting spot. I used pieces of recycled tire floor mat cut into pieces for the padding. 



We decided to put carpet up front as it will cut down on water noise and if you put skis up there is will keep them from banging the hull. This stuff was a pain in the butt to lay down, but we got it. You really will never see this, and i personally hate the way it turned out.



Now it was time to build the kick plate that the driver and passenger rest their feet on. We used foam to make a template of the bottom first as the original was ruined.



The top area was a different story... as I was able to use the original as a template.. YEAH!!





Once it was done and all test fitted, it was time to cut it out of wood.



Once we got the wood cut and got the rough shape cut out it was time to get it mounted in.



I needed a way to secure the kick plate down without screwing to anything permanent. So what i did is make a sacrificial mounting structure that I glued in for the kick plate to screw too.



I cut out the middle so that water could run out, and made an indention on the back of the kick plate so that the water did not get trapped.



Once that was dry, I screwed the kick plate down and then used peanut butter all around it... with the exception of the lower front. This will allow water to escape from the front it it gets there. Notice teh green stuff there. I ran out of cabosil to make Peanut butter, and used Bondo glass. It was terrible, and kicked off in about 5 minutes. 





I will tab all of this in after I get more cabosil and can make some more smooth peanut butter and make the seams smoother.

Thats it for the pictures on this update. Now here is about an hour of video that goes into more detail.