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1979 Aquasport 200CCP Rebuild

Old 06-22-2018, 09:28 AM
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Looks great! Really nice work.
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Old 06-29-2018, 09:02 AM
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Great build and looks great ! So when you made your console bigger you made a wood form then lined the form with what gel coat ? then layers of glass/matting,etc ? I'm in the process of starting a project on my C-Hawk 18 ft CC in removing the tank and while I'm at it I always wanted to make my console bigger and add a anchor locker up front but I will be new to working with fiberglass/resin etc.
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Old 06-29-2018, 09:52 AM
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Originally Posted by Big Guppy View Post
Great build and looks great ! So when you made your console bigger you made a wood form then lined the form with what gel coat ? then layers of glass/matting,etc ? I'm in the process of starting a project on my C-Hawk 18 ft CC in removing the tank and while I'm at it I always wanted to make my console bigger and add a anchor locker up front but I will be new to working with fiberglass/resin etc.
I used Aires and Divynecell foam panels and pegged them together with toothpicks. Then I epoxied in foam fillets. Basically it was the same as if I built it out of plywood. I did make a wooden base to hold the panels square when I glassed everything together. I used 2 layers of 1708 and a layer of 1 1/2 oz mat on the outside, a single layer of 1708 on the inside. It turned out rock solid.

One thing I learned working with the foam, is that the panels tend to warp a bit when you glass them. It required quite a bit of fairing. If I was building a console again, I would use Melamine panels to build a female mold. If you want to see a few more details on my console build you can check out my build thread on Classic Aquasport. https://classicaquasport.com/smf/ind...?topic=13659.0
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Old 06-29-2018, 10:11 AM
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So if I'm understanding this right your pinning the foam panels and putting them in a wood frame, then putting resin/fiberglass on the inside of that foam. Then when that cures your pulling out that initial foam w/resin on the inside and then put resin/fiberglass on the back side of the foam panels to seal it in and leaving the foam in there ?
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Old 06-29-2018, 11:01 AM
  #85  
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Originally Posted by Big Guppy View Post
So if I'm understanding this right your pinning the foam panels and putting them in a wood frame, then putting resin/fiberglass on the inside of that foam. Then when that cures your pulling out that initial foam w/resin on the inside and then put resin/fiberglass on the back side of the foam panels to seal it in and leaving the foam in there ?
I used no wood frame for my console. If you look at the 5th and 6th photo down you will see a melamine panel that I used as a base to hold things square while glassing. Other than that, no frame. I glued and pinned the foam together. When that cured, I routed the exterior corners to a nice radius. I glassed the exterior then I glassed the interior, exactly how you would proceed if made out of plywood.

if I did it again, I would make a mold. Glass the inside of the mold. Then, I would only add foam core to the dash panel and areas for switches and wiring.

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Last edited by mshugg; 06-29-2018 at 11:08 AM.
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Old 06-29-2018, 03:08 PM
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Kick ass
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Old 06-29-2018, 04:34 PM
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You do nice work!

On the console you mentioned the foam flexing some before fiberglassing both sides. I think you could bump up the thickness to 1-2" thick and it would stay rigid when glassing it. If you have alot of the foam you used on hand you could probably double it up by gluing it together.

Keep up the good work and thanks for posting pictures of it.
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Old 06-30-2018, 02:51 AM
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The problem isn’t really flexing, its warping. That is to say, when you glass one side the glass shrinks, warping the panel. Some people laminate the foam on a flat table. Once laminated the panels resist flexing and warping better.
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Old 06-30-2018, 07:01 AM
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That looks awesome, very similar to the CM Marine large console that I have just with the extra shelf/dash in the middle. Is that for cup holders and a spot to put phones? Where did you get that console door? Any guestimates on the finished weight?
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Old 07-01-2018, 02:33 AM
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My leaning post is CM. I looked hard at the CM console, but it was too deep front to back for my application. The CCP has a 48” coffin boy in front of the console, and I wanted to keep the feature. I kept the overall footprint and lines of the original Aquasport console, just simplified it and made it taller with a flush mount instrument panel.

There will be a dual stainless drink holder on the Starboard end of the flat. Plus I’ll be adding a keeper strip and probably a sea deck padd, so I can toss lures, hooks etc on the ledge.
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Old 07-01-2018, 03:23 AM
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Man your work is outstanding. I'm almost to the end of a scow rebuild and I know it takes tons of determination and skill my hats off to you sir 🖒
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Old 07-01-2018, 01:03 PM
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Originally Posted by mshugg View Post
The problem isn’t really flexing, its warping. That is to say, when you glass one side the glass shrinks, warping the panel. Some people laminate the foam on a flat table. Once laminated the panels resist flexing and warping better.
if you are having bad warping issues, you may want to switch to a vinylester resin.

The resin I got from Us Composites didn't warp at all when I was laminating a inner skin for the v20 transom I redid with arjay.
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Old 07-01-2018, 04:27 PM
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I’ve used a ton of vinylester in the rebuil. The outside of the console, the forward and aft bulkheads, the cockpit sole, and my coffin box are all done in VE. I find it more prone to warping than epoxy. I think it’s the quicker cure compared with slow epoxy mix.
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Old 11-26-2018, 05:26 AM
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It's been a while since I updated this thread, but I've been at it. I had Birdsall make me a new T top and and backrest for my leaning post. The top will be a bit oversized for a 20 footer, but I wanted the shade, and I don't like the looks of a small top. Most of my fishing is dead bait trolling, usually solo or with one additional, so I can get away with the larger top.

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I've faired and primed the cap. It was a but of work to get the radius and lines right on the gunwales, But I think they turned out well.

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I stripped off all the old paint on the bottom, first with chemical stripper and a pressure washer finishing with 80 grit paper. There were quite a few small voids and some keel rash. I repaired all of that under the boat, but then I discovered a slight hook in the aft hull, so I decided to flip the boat to finish the hull bottom.

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That catches things up. I will fill, fair and paint the bottom using VMC Performance Epoxy. And, I'll fair and paint the hull sides in Kingston Gray Quantum PU. Then, we'll turn her back over. Hopefully it will be the last time ever she's upside down.
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Last edited by mshugg; 11-26-2018 at 05:56 AM.
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Old 11-26-2018, 06:50 AM
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Very nice work! Bobby did the tower on my boat. Their work is top notch. You are going to ask yourself why you didn’t flip it to start. Makes it so much easier. I flipped my 28 bertram and took all the gelcoat off then added two layers of biax. The only way to do it.

Boat looks great.
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Old 11-26-2018, 08:55 AM
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I love binge reading rebuild threads !
Awesome work. Gray hull color choice is great. Keep us posted and continued success.
Best,Chris
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Old 11-26-2018, 11:06 AM
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Did I also see this over on classic aquasport? If it's not there it should be. You have tremendous fabricating skills and great abilities to innovate solutions to all sorts of construction issues. I has a 200ccp which was a great boat bone stock. This thing will be unbelievable when done.

--Kevin
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Old 11-26-2018, 12:34 PM
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Thanks DayTrip, Chris and Kevin for the kind words and encouragement.

Originally Posted by ktisdall View Post
Did I also see this over on classic aquasport? If it's not there it should be. You have tremendous fabricating skills and great abilities to innovate solutions to all sorts of construction issues. I has a 200ccp which was a great boat bone stock. This thing will be unbelievable when done.

--Kevin
Yes, I've got the full rebuild posted on Classic Aquasport. Here's a link: https://classicaquasport.com/smf/ind...opic=13659.300

This thread is condensed a bit.
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Old 11-26-2018, 05:06 PM
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Thanks for the update, its really looking good.
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Old 11-26-2018, 05:25 PM
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Wow. Superb talent. By the way, I had a 1978 dual console Aquasport. To this day it was the best boat I have ever owned.
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