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290 Coastal Soft Cockpit/Bad Gas Tank Can of Worms

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290 Coastal Soft Cockpit/Bad Gas Tank Can of Worms

Old 01-17-2020, 09:34 AM
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Default 290 Coastal Soft Cockpit/Bad Gas Tank Can of Worms

So when I bought my boat five years ago there was a 6-8" soft spot in the floor, not a big deal. Fast forward til now and the whole area is sft and now getting cracks all over. Time to cut it out and re-core. Will be a perfect time to pull the gas tank to inspect. Hopefully the 17 years of salt water use have been good the the bottom side of the tank, the top and sides look really good. If it's corrosion free, it will be prepped and painted with coal tar epoxy. Wellcraft uses 6x6 plywood squares to core thier decks. Notice in the photos the wet mulch I removed where it's rotten and the other wood sitill looks like new. Everywhere I've cut into the boat where it's cored, the wood has been real good. I'm just lucky I have the experience, tools and shop to do this repair myself.








Last edited by BoatHaus; 02-12-2020 at 12:55 PM.
Old 01-17-2020, 11:40 AM
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What was causing it to rot in that spot?
Old 01-17-2020, 11:54 AM
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Originally Posted by RogueAngler View Post
What was causing it to rot in that spot?
most likely, from the circular inspection hatch. Im sure the intrusion started there
Old 01-17-2020, 12:14 PM
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Looking forward to seeing how this goes.. Back out a little on the pics if you can. Its hard to get a feel for the full project and I know the 29 coastal very well
Old 01-17-2020, 12:44 PM
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I believe it started from two places, as mentioned above, the inspection plate but also found several voids in the back side of the laminate exposing the core. I keep an iced cooler in the cockpit 90% of the time. There is constantly standing water under the cooler which is where a lot of the rot is the worst. The glass looks fine but i can't help but wonder if the water could permiate thru the gel and glass over time?? I'll keep the photos coming as there are plenty of 290's out there that all have wood cockpits
Old 01-23-2020, 05:55 PM
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Getting the tank out was a real bitch as they have no lift tabs welded on. Nonetheless, she's out and in extremely great condition for being 17 years old. Proof, foam should not go around an aluminum tank. The supply hoses are also in great shape. I feel lucky for a change. The floor is currently being re-cored with coosa board and I'll prep the void where the rotten wood was in the part of the deck still in the boat and fill with epoxy paste andshove 1/2" foam or coosa into the paste. All repairs are being done with west system epoxy so I know it will be forever. The tank will be prepped with 80 grit, acid washed and coal tar epoxied. I'll install new shut off valves and hoses and she'll be good for another 17 years. While she's down I wanted to fix the deck cracks that have been repaired several times. This time I'm doing it myself using WS Epoxy instead of polyester again. I start grinding and holy crap, air void after air void, imean 6" long air. what the heck?? No wonder it always cracks again. I ground it down to almost nothing. I'll fill it with 1708xm/cloth tape and 3/4 mat, no filler. I won't be doing this again. More pics tomorrow






Last edited by BoatHaus; 01-23-2020 at 06:04 PM.
Old 01-30-2020, 11:20 AM
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DAMNIT!!! Cleaning up the gas tank and knock off a chunk of fiberglass attached to the tank right where the drain for the tank compartment is and there's a friggin hole. A $2500 friggin hole. Oh well, on the bright side a 17 year old boat with a new gas tank is always better than a 17 year old tank regardless. I keep thinking I've replaced everything, what else can go bad? I gotta stop saying that because every time I do something else reminds me its time to spend more money. At least I basically have a new boat now. Minus the fiberglass, windshield (which is being removed, line X'd and replaced w new rubber), the cabinets and the hard top frame. Literally every other component I've replaced and or upgraded. I sure hope this is it for a while but man I hate when something on the boat is broken or not working. Pictures soon

Last edited by BoatHaus; 01-30-2020 at 02:38 PM.
Old 02-04-2020, 07:16 AM
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keep the updates coming, I cant believe the way you ground down the side of the cap. I would have never done that. But its not my boat so i'm looking forward to seeing how it comes out. maybe one day ill get that aggressive and know how to do it,
Old 02-04-2020, 08:12 AM
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Originally Posted by BoatHaus View Post
DAMNIT!!! Cleaning up the gas tank and knock off a chunk of fiberglass attached to the tank right where the drain for the tank compartment is and there's a friggin hole. A $2500 friggin hole. Oh well, on the bright side a 17 year old boat with a new gas tank is always better than a 17 year old tank regardless.
Even brighter side - imagine if you'd had a leak after refinishing the tank and completing the job. I know it's expensive, but strikes me that someone is looking down on you very favourably!
Old 02-11-2020, 07:14 PM
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So I opened the can of worms and I dodged a bullet. Besides the floor, i chopped out a sub floor and aft bulkhead . Positive is i have unprecedented access to my bilge and will give it a full re rig and paint. Bottom line is this is a lot of work and one job morphs into a dozen more but at the end of the day it's gotta be done right

This will be sanded smooth, gaps filled w WS610 then covered w two layers of 1708




Even the back seat is being re cored. It was broke so i thought it was rotten. Turns out it had a weight limit. No more fatties




Gas tank sub floor

Last edited by BoatHaus; 02-11-2020 at 08:02 PM.
Old 02-12-2020, 12:22 PM
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prepped w 80 grit and coal tar epoxied the new tank today. This tank will never need to be replaced again. New sending unit, valves, hoses, fuel water filters and deck fill. Much better than OEM



Last edited by BoatHaus; 02-12-2020 at 12:45 PM.
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Old 02-12-2020, 12:24 PM
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must have been a thing with those coastals, been seeing them with cracks running almost the entire gunwale, when you grind into them its a very airy layup. Have the same boat here we had to do the entire gunwale on the side he docks on

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Old 02-12-2020, 12:38 PM
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Yeah, as you can see in the photos, it was a very poor and thin layup. Hopefully 3 1708's and a few oz of mat using west system will keep them from returning. I may also add a 2408 to the areas I can reach from inside. I ground down 1/4" from the transom to just fwd of the spring cleat

Last edited by BoatHaus; 02-12-2020 at 12:44 PM.
Old 02-12-2020, 12:44 PM
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do you gelcoat over the west?
Old 02-12-2020, 12:47 PM
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Originally Posted by Raybo Marine NY View Post
do you gelcoat over the west?
yes, I'll fair the glass trying to use as little filler as possible then gel. Using WS on all my secondary bonds and repairs
Old 02-12-2020, 12:58 PM
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Raybo, go around the one you have in your shop and pound on the hull with your hand and hear the rattlebox echo chamber. I just spray foamed in my entire cabin liner using a DOW Frothpak and WOW what a difference in the sound of the hull. I can't wait to get her back in the water and hit some waves
Old 02-12-2020, 01:01 PM
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Default Epoxy

Nothing wrong with west but it’s expensive I’ve ordered from the following with no issues and both shipped quickly.

Raka, Inc. 772-489-4070

boatbuildercentral.com
Old 02-12-2020, 01:48 PM
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Originally Posted by BoatHaus View Post
Raybo, go around the one you have in your shop and pound on the hull with your hand and hear the rattlebox echo chamber. I just spray foamed in my entire cabin liner using a DOW Frothpak and WOW what a difference in the sound of the hull. I can't wait to get her back in the water and hit some waves
and I think this contributes to the gunwale cracking. It lays against a pole or bulkhead and something goota give, usually the gunwales due to the shape . the hull is spread out so its fine
im sure the foam will make a big difference
Old 02-12-2020, 08:52 PM
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You're lucky to have the knowledge and tools to do this project. I also have a 2005 model year 290, but I haven't experienced any of the issues you mentioned so far. I would need to hire an expert to do that job and that would cost me a bunch of dough. Best of luck with your project and keep the updates. I will be following your progress.
Old 02-12-2020, 09:17 PM
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Great job. Are you using Coosa for the recore? Tanks look great!

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