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1979 Aquasport 200CCP Rebuild

Old 09-28-2017, 10:38 AM
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Default 1979 Aquasport 200CCP Rebuild

I started this rebuild in April, 2016. I'm getting close to wrapping up the glasswork and moving to sanding painting and fairing. The full rebuild is documented over on Classic Aquasport, but I thought I'd post some highlights here to get a bit more traffic.

The boat will get a full transom with Armstrong bracket. Most likely power will be a 200 Sizuki. The mission will be fishing, primarily trolling the waters of East Central Florida. Access to all systems for easy maintenance will be a top priority too.

She started out pretty rough, but since 1985, when I ran a 170 much further out than a 17 foot boat belongs, I've had a soft spot for Aquasports.

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Te previous owner had replaced the fuel access hatch with a piece of heavy counter top material. The transom and deck were soft and the wiring was a mess.

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Old 09-28-2017, 10:51 AM
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Here she is stripped down and getting a new transom. It's 2 layers of 28Lb Carbon Core, similar to Coosa.

I used a Melamine mold to fill in the transom cutout in the outer skin before patterning and fitting the core.

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Old 09-28-2017, 10:56 AM
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Excellent. Looking forward to seeing more pictures. Thank you for sharing your project. Many here love this stuff including myself.
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Old 09-28-2017, 10:57 AM
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Here the inside transom is glassed and tabbed in to the hull and the cut out end of the stringers are tabbed in, filled and glassed.

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Old 09-28-2017, 11:03 AM
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This is where the project becomes much bigger. The reinforcing plywood in the hull deck joint was in such bad shape that I decided to remove the liner, reenforce the hull deck seem and go to a cap only rebuild.

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This is the hull side of the hull deck seem reenforced with multiple layers of 1708.

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Old 09-28-2017, 11:03 AM
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Stringers foam filled?
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Old 09-28-2017, 11:11 AM
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I used leftover Carbon Core from the transom to raise the stringer height and used 2" Divynecel H130 to form the bulkheads to create fuel tank wel, a large ice/fishbox and smaller compartment.

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Old 09-28-2017, 11:18 AM
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Nice work! I have an osprey 175 and its a pretty great little boat. I'm doing something similar to what you're doing there to a 20' seacraft and the osprey will be for sale when I'm done. I'll go over to Classic Aquasport and check out the full build.
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Old 09-28-2017, 11:18 AM
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Added wedges of Divynecel to form ledge to support the outer edge of the cockpit sole, and covered with biax.

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Old 09-28-2017, 11:21 AM
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Originally Posted by captbone View Post
Stringers foam filled?
Absolutely. The foam in the stringers was in good shape, so I just refilled the aft section of the stringers with 4LB foam when I tabbed them back in. The area under the center compartments is filled with 4LB foam too.
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Old 09-28-2017, 11:24 AM
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Excellent project. Always wanted to see how you go from 2 piece construction to 3 piece. It looks like you are doing quality work.
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Old 09-28-2017, 11:25 AM
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Nice. What are you using for resin? Epoxy, Vinly, Poly?

Amazing project.
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Old 09-28-2017, 11:33 AM
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Finishing the under deck work, foaming in the side voids, fitting the fuel tank and painting the bilge and holds.

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I used the Pascoe method to secure the tank. There are PVC strips glued to the bottom of the tank to isolate it from salt water. I made a slight modification by glueing Male PVC chocks to the tank corners and glassing mating chocks to the stringers and bulkheads.

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Old 09-28-2017, 11:45 AM
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The cockpit sole is made of 3/4" T92 Airex foam covered with 2 layers of 1708 top and 1 layer bottom.

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I bought ready-made Hatches for bilge and storage access. This far into the build, I'm willing to trade a little money for time.

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The Fuel tank inspection hatch required a bit more work. I routed out the edge of the foam, filled with thickened epoxy and formed a lip.

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Old 09-28-2017, 11:48 AM
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I laminated 8" x 8" x 5/8" Glass pads and routed them into the sole for T top attachment.

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Old 09-28-2017, 11:54 AM
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This is the cockpit sole going in. The outer foam has been sealed with thickened pigmented epoxy. My brother in law drew the short straw, so he got to hang out in the fishbox and apply the thickened epoxy mix forward. We weighted the sole with 5 gal buckets filled with water and once it was cured, tabbed it in.

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Old 09-28-2017, 11:58 AM
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Originally Posted by captbone View Post
Nice. What are you using for resin? Epoxy, Vinly, Poly?

Amazing project.
Thanks. I'm using epoxy for most things, but for fabrication of some parts, I'm using vinyl ester. For example the cockpit sole was fabricated with VE then bonded and tabbed in with epoxy.
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Old 09-28-2017, 12:05 PM
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Tubes for the scupper were fabricated on a mold of PVC covered with packing tape. They were then fitted onto/into small stringers that will support them.

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Old 09-28-2017, 12:13 PM
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I used some 1/2" foam to back up the coamings forward. Then I used leftover carbon core to make the aft gunwales.

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Old 09-28-2017, 12:14 PM
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freaking awesome work!!

I was worried you were going to leave the cut foam like that and then I saw you skimmed it...

The only thing I don't see are limber holes near the transom through the stringers...I guess you are assuming no water is going to get on the outside of the stringers?
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