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Custom Boston Whaler Flats Boat Build

Old 05-25-2010, 07:51 PM
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Default Custom Boston Whaler Flats Boat Build (FINALLY adding pictures)

I promised the guy building the boat that I'd post this on several of the boards that I frequent.
I have a 1970 Boston Whaler that I bought a couple of years ago from a guy in Greenville, NC. I fished the little boat for a couple of years, but she was pretty rough. All of the mahogany was splitting, the gel coat was cracked pretty badly.
Not to mention that its a 13 foot boat with a 65hp Mercury short shaft on the back!! We would literally outrun jet skis in this thing! I'm guessing that it was a tick over 60mph??
Well, after seeing (and falling in love with) the Chaos flats boat, I was hellbent on getting one. As the saying goes, "Its cheaper to keep her" I decided to get the whaler customized into my own version of a flats boat.
I bought a Johnson 50hp freshwater engine, a perfect little center console, rigging, cables, electronics and some of the misc stuff that I'll need for the build.
I found a shop in Charleston, SC called High and Dry boatworks www.highanddryboatworks.com who specializes in customizing and restoring Whalers. She will have Divynacell front and rear decks (all vacuum bagged), PlasTeak cockpit, real teak toe rail, poling platform, a 12 gallon tank moved to the bow, moving the batteries to the center console, raising the transom and recessing all plimbing/wiring into the deck. We're also adding built in drink cooler and dry storage as well as a couple of built in tackle lockers. (after all, storage is at a premium in a 13 foot boat).
Trust me, it can be done. He has one that he built last year to show me. Using the Divynicell and moving the weight forward, it still uses the original waterline!
I was thinking of posting progress pictures of the build. Anybody intested?

Last edited by MikeWinn; 04-21-2012 at 04:42 AM.
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Old 05-25-2010, 08:10 PM
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Of course...bring them on
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Old 05-25-2010, 09:23 PM
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Post 'em. Start with a before pic and bring us through the process.
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Old 05-26-2010, 07:56 AM
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I did a similar project on a 15' whaler for casting in the back by for stripers. Although it sounds like yours will be much cooler. Please post your pics! This project sounds amazing.

By the way, I love that 16 chaos too.
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Old 05-26-2010, 09:38 AM
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Looking forward to your pictures. Can you still purchase PlasTeak? I read they lost a patent infringement case brought by Flexiteek. I think the company is enjoined from selling PlasTeak in the US, which is disappointing as it was about $20-35 less per sq ft. than the competitors.
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Old 05-26-2010, 12:13 PM
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www.highanddryboatworks.com
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Old 05-26-2010, 12:26 PM
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There wa a story in Florida Sportsman about 20 yrs ago about a guy and his young son that took a 13 ft whaler for a few days of fishing and camping in the keys. These old Whalers are great boats and a great fishing platform especially the older models up to about 17 ft
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Old 05-26-2010, 08:12 PM
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I'm waiting for them to send me pictures. As SOON as they're here, I'll start posting them. I was REALLY impressed with the quality of their builds. On their site, there's a 15' "Mic's 15" the one with the teak console (that kind of looks like a casket)...That thing has a 200 HPDI on the bck with a jackplate (and a hot foot, no less). In the pictures on their site, it ONLY has a 150....They say that with the 200 it runs in the high 80s.....
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Old 01-16-2011, 07:13 AM
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OK...So it took a while. I finally have tons of pictures. I'll start posting them as soon as I can.

Last edited by MikeWinn; 01-16-2011 at 05:01 PM.
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Old 01-16-2011, 04:47 PM
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These are the before pictures. Yes, it was pretty rough. 40 years old and has seen better days. More to come.
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Old 01-16-2011, 04:54 PM
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Then came the grinding. They ground off all of the gelcoat (yes, they ground off more than in the pictures.) Then came fixing the holes. You can see by the bright foam that there wasnt any water intrusion. Then the entire hull was reglassed inside and out.
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Old 01-16-2011, 04:59 PM
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More grinding....(You can tell that Kurt doesn't like grinding very much). Then the transom notch was filled in. We saved the original BW serial number. In the last picture you can see the foam lining starting to go in for the isulated cooler and the insulated fish box.
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Old 01-16-2011, 05:41 PM
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WOW! Keep the pictures coming!
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Old 01-16-2011, 08:08 PM
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Nice work, What are you using for the boxes that your glassing in. Some of it looks like foam but the other looks like 1" glass across the front. Thanks Andrew
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Old 01-16-2011, 08:24 PM
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The green is divinycell. The decks are another composite, white/opaque almost like a corrugated material.
The foam for the cooler and fish box is some sort of a 3" foam that is impermeable to epoxy and resin. He sandwiched the foam between divynicell and glassed it all together for structural rigidity for walking on and for lateral stability.
The starboard compartment is watertight. The cooler (center) and fish box (port) drain into the bilge.
You can also see the rigging tube on the starboard aft bulkhead. He cut a channel through the floor then glassed in the rigging tube.
He also leveled out that God awful curve in the floor with structural foam, then vaccuum bagged it all together.
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Old 01-17-2011, 05:05 AM
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First picture is the transom coming together. Note the recessed rigging tube. The grey tube going into the bilge drains the bow lockere. Its recessed also.
Second picture (looking forward) is the recessed rigging tubing in the floor and the grey drain tubing for the bow.
Third picture is the recessed tubing...again. Also all of the drain grooves n the floor were filled.
Next the annoying "V" in the floor was leveled off with foam and a drain for the cockpit was added.
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Old 01-17-2011, 05:15 AM
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Excess foam was cut out, and the floor was leveled with a very slight contour for drainage. Then it was sanded down and vaccuum bagged. You can see the forward bulkhead starting to come together...And of course is dog...Lazy (but sweet) Weimeraner!!
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Old 01-17-2011, 05:34 AM
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Originally Posted by MikeWinn View Post
Excess foam was cut out, and the floor was leveled with a very slight contour for drainage. Then it was sanded down and vaccuum bagged. You can see the forward bulkhead starting to come together...And of course is dog...Lazy (but sweet) Weimeraner!!
A dog sleeping on the shop floor is an important part of any major project like this.
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Old 01-17-2011, 05:43 AM
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The following pictures are NOT my boat. This was more or less the inspiration for my boat. But do you see how the rigging and wiring are all exposed? Thats how the old Whalers were. I thought that was kind of rough looking. I wanted more of a smooth, refined look to her (Like a Chaos).

The Chaos in the pictures belongs to THT member Infintas. http://www.thehulltruth.com/boating-...haos-16-a.html

I HOPE that she turns out nice...More like a hybrid between the Clearview and the Chaos. I am following a lot of the style points of the chaos though (teak, speaker placement, blue LEDs, and a more "finished" look to her).

Do you guys have any suggestions while she's still being built???
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Old 01-17-2011, 06:37 AM
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Very nice. If I wasn't so stuck on keeping my Montauk original, even with dings and old cushions, I'd love to drop her at High and Dry. I've seen their work before - on Whalers and others...
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