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Hull as is
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Front view of hull before any work
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Here is the condition of the interior of the boat, the back to back seats will be retained as they are in good condition.
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Interior before
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Splashwell/aft of boat
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Notice the messy layout of the stern. A rear wall will be incorporated into the splashwell, the fuel tank will be installed under deck and the rear spalshwell seats will be upholstered with cushions.
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The idea is to install a walkthrough windscreen much like that of Tengals123. The only issue with this is the limited dash space. A solution will need to be derived.
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Bow/Dash
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Hull stripped
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Side view of hull with all fittings removed
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Rear view
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Hull stripped 2
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Dash emptied
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All instruments removed, will look vastly different in a months time.
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The floor has been cut out so that the under floor mods can occur
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Floor cut out
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Aft section of floor
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The current aft section of floor is to be modified to accept an underfloor fuel tank. The tank is 90 litres and its dimensions are 1600x410x160mm. The rear bulkhead will need to be removed in order to fit the tank. Additional bulkheads will be installed to aid in stength
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The bow section of floor. An underfloor storage section will be installed here. this will measure 850mmx350mmx180mm. This will be able to be used as a kill/ice box.
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Bow underfloor
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Fuel tank flooring
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Here is a picture of the fuel tank floor section before installed into the boat. Built out of 12mm structural plywood and will allow for tank expansion.
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The hull has been moved into the old barn shed to keep it out of the rain when fiberglassing and sanding. It will be covered with a tarp to save it from the possums.
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Change of Location
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Bulkheads installed
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Here are two of the new bulkheads installed. These are in place for the two storage sections in the floor. The bow storage section is a fish kill box and the stern section is the for the under deck tank. The bulkheads were laminated from two pieces of 12 mm plywood with a layer of 450 gm chop strand mat between.
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Here is the walkthrough cut. Quite a large area, bigger than i had anticipated. This will be great for direct anchor access and walkthrough panels will be cut to form the sides. A screen will be custom made by Plasview in Braeside, Melbourne.
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Walkthrough Cut
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Floor jacks cut
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Here are some of the strips of 12 mm plywood that will jack the floor up by 12mm. This should provide more room for the underdeck fuel tank.
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As can be seen, the plywood has been bonded to the existing stringers. A product called probond was used and was bought from Fiberglass International. It is a premixed solution of polyester resin and microballoons allowing convenience. Thanks to Doug Grant for the advice.
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Floor jacked up complete
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New Dash
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Here is the limited dash space left after the walkthrough cut. I plan to build a dash panel out of 12mm ply which will sit above the current dash. This will allow plenty of dash space for gauges. The holes in the current dash will be filled in to allow for the new steering kit and switch panel.
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Me being silly. I used screws which were too long and went straight through the hull! This should be a relatively easy fix but wouldn't have happened if i hadn't rushed.
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Oops!!
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17/08/06 Update Fuel Tank Section in
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The fuel tank compartment has been bonded to the hull using probond. The insides will be glassed to the hull to give additional strength and really key the section to the hull.
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The forward view of the tank section. Notice the probond bed. The section will also have to be built up as the stringers have been. What I am doing is putting the plywood in place (not screwed down) and then using a router to level the tank section according to the plywood floor. This will mean the access hatch should sit true.
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Tank section
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Stern Floor pieces
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The port and starboard floor pieces have been cut and shaped. These need to be coated a couple of times in poly resin to waterproof the ply.
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Sitting losely. Gaps should be easy enough to fill up. Remember, the tank section needs to be built up and hence the gap between that and the floor.
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Stern Floor pieces
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Centre Floor Piece Cut
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Centre Floor piece has been cut and loosely seated.
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As described
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Stern and Centre floor pieces
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Bow floor piece cut
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The bow floor piece has been located. Basically the floor pieces are fully cut and waiting to be glassed back.
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I didn't have enough material to make a full piece so this was the best compromise. A couple of strips of 12 mm ply will fill that join. Note that the bow storage compartment is yet to be cut from the plywood flooring.
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Bow and Centre piece gap
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Flooring fully cut
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Sitting very loosely in position. Starting to really look like a boat again. Should be able to glass it all in the next couple of days...
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Two twin halogen tripod lights have been bought so that work can go well into the night. Since stored on a farm, there is no restriction with noise, just the cold...
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Let there be lights
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Stringers glassed
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The stringers have been glassed to the tank section. 450 gram chop strand was used
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Probond was used to bed the forward bulkhead into place much like similar sub floor elements. The bulkead (like all the others) still needs to be glassed to the stringers to really key them to the hull.
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Forward bulkhead in
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bungs filled
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The side bungs were not draining very well as the angle that they were drilled on meant that not all water could escape. These have been filled using International 'Epifill'. It is a two part epoxy filler and should do the job nicely.
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A tiny bilge is what is left. A bilge pump will be installed and this should remove any unwelcome water!
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New Bilge
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Bow section sides in place
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The bow section storage is practically complete. All that requires is glassing of the section to waterproof and the sub floor plywood installed. Then this can be filled with ice and beers and we are away.
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Well the subfloor is now finally complete and ready to have the plywood sheets fully permanently installed. Looking forward to moving onto the walkthrough and rear wall then hitting the sanding.
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Sub-floor complete
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Kill tank Drainage
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40mm PVC pipe has been fitted to aid in the drainage of the new kill tank. This will channel the stinky fishy water to the transom area for better drainage. Currently the plan is to install the pvc to just short of the current bungs to drain out those, but am toying with the idea of installing another bung to eliminate any of the kill tank water contacting the inside of the hull.
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The PVC has only been installed to the fuel tank area untill a decision has been made on the ultimate drainage solution. A joiner has been fitted for the PVC extension.
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Kill tank Drainage II
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Kill tank Drainage III
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The pipe was installed using probond into a predrilled 44mm hole with a hole saw. The PVC will be trimmed flush with the bulkhead and a bung installed in the PVC. The PVC elbow was bedded down with some more probond and then a couple of strip of chop strand matting were used to secure the PVC to the hull. Hopefully this pipe will never move.
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After two thick coats of resin on the underside, the rear flooring has been installed. Probond was applied to the stringers and frames and then plywood screwed down to apply pressure.
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Rear floor sections in.
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Probond seeping
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A good indicator of a good join... (hopefully)
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The middle flooring piece has been installed in the same manner as the first.
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Middle piece in
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Bow section floor
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Same procedure again
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A close-up of the newly installed kill tank. Very happy with the new layout....
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Kill tank
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Floor to Hull Joint filled
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The floor to hull joint was filled with a mixture of resin and q cells. This should aid in sealant as well as provide more rigidity into the floor as all gaps are now eliminated.
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The floor has now been glassed. Still needs a trim however. 450 gm chopstrand was used and it was keyed into the hull approximately 4 inches overlapping the plywood
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Floor Glassed
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Floor Glassed - Bow
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Just a view of the bow area... The gaps have been filled with smaller cuts of plywood and then crevices filled with the filler mixture of q cells and resin.
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The pipe has been lengthened to drain down to the transom.
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Drainage Extended
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Drainage outflow
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Here is where the bow kill tank will drain to. Unfortunately, it was going to be too complicated to drain into the bilge (located above the pipes outlet) as the fuel tank was in the way and the only other possible way to do so was to cut into a stringer (which i didn't want to do.). Here the water drains practically to the bung and most smelly water should escape pretty easily. A good blast with the pressure washer through the bung should see the smelly water escape.
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The stringer had to ground down to fit the fuel tanks depth. It then had layers of chop strand applied to bring it back to an adequate strength.
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Stringer ground down then strengthened
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Walkthrough Panel templates
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Templates were made to aid in accurate cutting of panels
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The panels have been cut with the aid of the templates. They will be fiberglassed either side before being installed.
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Walkthrough panels cut.
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Splashwell extenders + Seat mounts cut
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As per the description above
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Starting to look good...
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Walkthrough Panel Dryfit
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Bow section ground
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The bow was ground so that flowcoat can be applied. This area will be located behind panels with access hatches and wont be carpeted. Flowcoat should make it look pretty nice and also provide excellent waterproofing.
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Unfortunately a year ago I didn't think ahead and modified the splashwell resulting in it being too narrow for hydraulic steering. These will be bogged into the splashwell to give me plenty of room. I couldn't think of an easier way to do so....
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Splaswell extenders
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Splashwell cut
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This is the area where the splashwell extenders will be bogged in.
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A front view of the new dash. Since I cut the front deck, dash space is now limited (basically non existant) so a dash had to be made so my flashy faria gauges could fit.
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Dash
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Basic Dash Mould
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We wanted the dash to be curved, so we had to make a very simple and one off mould. It is simply cardboard that has been wrapped around the shape of the dash. The cardboard was scored to allow it to bend and then waxed paper was applied to stop the fiberglass sticking to the cardboard.
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The Seat stiffener/Rear Wall Mount has been cut and fiberglassed. It is now ready to be installed.
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Seat stiffener/Rear Wall Mount
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Seat stiffener/Rear Wall Mount Bogged in place
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The mount has been bogged in place. It should provide the fiberglass seats with lots of rigidity. These were flexing a fair bit before hand and i am sure would later crack if some form of stiffener was not added.
The stiffener will also double as a backing top mount for a removable upholstered wall that will be installed.
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Probond was pushed into the crevices to ensure a good bond. I have decided to trim the seats off flush with the mounts, I believe it will make them look better and also stronger.
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Stiffener bogged
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Front Walkthrough Panels Bogged
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The front walkthrough panels have been bogged in place. The bow section has also been predominantly flowcoated.
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This is what will be seen through the panels hatch and hence the need for flowcoat.
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Bow flowcoat
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Front walkthough closeup
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A closeup of the panel to hull join for the front walkthrough panel. This will need another run of filler but should still be pretty rock solid.
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Two more panels are in and the remainder of the bow area has been flowcoated.
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More panels in
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Walkthrough Panels Starboard Side
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Here is a close-up of the starboard side walkthrough panelling. The joins are still very rough and will require some sanding and filling but you are able to get an idea of what it all should look like.
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The dash has been cut and bogged into place. Hopefully when sanding and glassed to the hull it looks half decent... fingers crossed.
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Dash cut and bogged in place
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Rear Stiffener
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Looking aft from the bow. The hull is now really starting to come together. It is getting exciting.
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Out with the old and in with the new. The old inline 6 merc has been replaced by this massive 135hp V6. Should get the little haines planing quickly!
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New Donk!!
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Engine
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Just another view of the engine.
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