Notices
The Boating Forum

1979 Aquasport 200CCP Rebuild

Old 09-28-2017, 10:38 AM
  #1  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
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.

Name:  Side_Bow_Quarter.jpg
Views: 4397
Size:  277.9 KB

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.

Name:  Tank_Hatch.jpg
Views: 3821
Size:  125.4 KB

Name:  Starboard_Battery.jpg
Views: 3800
Size:  250.3 KB
Likes:
Old 09-28-2017, 10:51 AM
  #2  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

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.

Name:  Transome_Mold.jpg
Views: 3821
Size:  210.2 KB

Name:  Transom_Skin_Outside.JPG
Views: 3810
Size:  196.1 KB

Name:  Transom_Skin.JPG
Views: 3798
Size:  193.0 KB

Name:  Transom_Template_on_Sheet.jpg
Views: 3810
Size:  213.7 KB

Name:  Transom_Clamped_Inside.JPG
Views: 3808
Size:  217.6 KB

Name:  Transom_Dry_Fit_ext.jpg
Views: 3805
Size:  251.2 KB
Likes:
Old 09-28-2017, 10:56 AM
  #3  
Senior MemberCaptains Club Member
 
Join Date: Mar 2003
Location: United States
Posts: 10,174
Likes: 0
Received 2,194 Likes on 1,000 Posts
Default

Excellent. Looking forward to seeing more pictures. Thank you for sharing your project. Many here love this stuff including myself.
Old 09-28-2017, 10:57 AM
  #4  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

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.

Name:  P7210020.jpg
Views: 3745
Size:  169.0 KB

Name:  Stringer_Extension.jpg
Views: 3759
Size:  234.1 KB

Name:  IMG_1176.JPG
Views: 3710
Size:  269.6 KB
Old 09-28-2017, 11:03 AM
  #5  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

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.

Name:  Liner_Lifted.jpg
Views: 3740
Size:  189.8 KB

Name:  Liner_on_Blocks.jpg
Views: 3810
Size:  285.8 KB

Name:  Cap_From_Bow.jpg
Views: 3745
Size:  227.8 KB

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

Name:  Hull:Deck_Reenforcement_2.JPG
Views: 3781
Size:  66.6 KB
Attached Images  
Old 09-28-2017, 11:03 AM
  #6  
Senior MemberCaptains Club Member
 
Join Date: Mar 2003
Location: United States
Posts: 10,174
Likes: 0
Received 2,194 Likes on 1,000 Posts
Default

Stringers foam filled?
Old 09-28-2017, 11:11 AM
  #7  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

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.

Name:  Bulkheads_Looking_Aft.jpg
Views: 3687
Size:  123.1 KB

Name:  Drains_2.jpg
Views: 3702
Size:  126.3 KB

Name:  Storage:Fuel_Deck_Dry_Fit.jpg
Views: 3697
Size:  128.9 KB

Name:  Center_Compartments_Aft.jpg
Views: 3695
Size:  130.0 KB

Name:  Center_Wells_Glassed_Foamed.jpg
Views: 3667
Size:  130.1 KB
Old 09-28-2017, 11:18 AM
  #8  
Senior Member
 
Join Date: May 2016
Posts: 275
Received 442 Likes on 189 Posts
Default

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.
Old 09-28-2017, 11:18 AM
  #9  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

Added wedges of Divynecel to form ledge to support the outer edge of the cockpit sole, and covered with biax.

Name:  Deck_Ledge_Close-Up.jpg
Views: 3759
Size:  224.3 KB

Name:  Deck_Ledge_Tabbed_In.jpg
Views: 3698
Size:  160.1 KB

Name:  Livewell_Drain_Chase.jpg
Views: 3764
Size:  228.4 KB
Old 09-28-2017, 11:21 AM
  #10  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

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.
Old 09-28-2017, 11:24 AM
  #11  
Admirals Club Admiral's Club Member
 
Join Date: Sep 2014
Location: Florida
Posts: 1,609
Received 463 Likes on 273 Posts
Default

Excellent project. Always wanted to see how you go from 2 piece construction to 3 piece. It looks like you are doing quality work.
Old 09-28-2017, 11:25 AM
  #12  
Senior MemberCaptains Club Member
 
Join Date: Mar 2003
Location: United States
Posts: 10,174
Likes: 0
Received 2,194 Likes on 1,000 Posts
Default

Nice. What are you using for resin? Epoxy, Vinly, Poly?

Amazing project.
Old 09-28-2017, 11:33 AM
  #13  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

Finishing the under deck work, foaming in the side voids, fitting the fuel tank and painting the bilge and holds.

Name:  Bilge_Paint_Looking_Forward.JPG
Views: 3730
Size:  31.1 KB

Name:  Fwd_Hold_Insulation.JPG
Views: 3649
Size:  117.5 KB

Name:  New_Chases.JPG
Views: 3705
Size:  47.4 KB

Name:  Bow_Foam_Trimmed.JPG
Views: 3754
Size:  244.5 KB

Name:  Flotation_Foam_Pour_Complete.JPG
Views: 3726
Size:  52.2 KB

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.

Name:  Tank_Glued_Down.JPG
Views: 3721
Size:  39.8 KB

Name:  Tank_Secure.jpg
Views: 3685
Size:  144.9 KB

Name:  FW_Holds_Painted.jpg
Views: 3684
Size:  106.1 KB
Old 09-28-2017, 11:45 AM
  #14  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

The cockpit sole is made of 3/4" T92 Airex foam covered with 2 layers of 1708 top and 1 layer bottom.

Name:  Cockpit_Sole_Layout_on_Foam.jpg
Views: 3669
Size:  139.7 KB

Name:  Cockpit_Sole_Dry_Fit_Before_Glass.jpg
Views: 3687
Size:  108.2 KB

Name:  Sole_Top_Glassed.jpg
Views: 3677
Size:  118.2 KB

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.

Name:  Deck_Hatches_Installed.jpg
Views: 3685
Size:  114.1 KB

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.

Name:  Fuel_Inspection_Port_Routed_Edge.jpg
Views: 3711
Size:  192.3 KB

Name:  Fuel_Inspection_Port_Fillet.jpg
Views: 3709
Size:  201.4 KB
Old 09-28-2017, 11:48 AM
  #15  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

I laminated 8" x 8" x 5/8" Glass pads and routed them into the sole for T top attachment.

Name:  Glass_Pads.jpg
Views: 3709
Size:  172.2 KB

Name:  Routed_Pad.jpg
Views: 3663
Size:  132.4 KB

Name:  Glassed_Pads.jpg
Views: 3661
Size:  189.0 KB
Old 09-28-2017, 11:54 AM
  #16  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

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.

Name:  P2180017.jpg
Views: 3685
Size:  207.0 KB

Name:  Cockpit_Sole_Glue_and_Weights.jpg
Views: 3662
Size:  191.1 KB

Name:  Deck_Cap_From_Stern.jpg
Views: 3671
Size:  187.5 KB

Name:  Deck_Fillet_Tabbed.jpg
Views: 3671
Size:  250.0 KB
Old 09-28-2017, 11:58 AM
  #17  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

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.
Old 09-28-2017, 12:05 PM
  #18  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

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.

Name:  Scupper_on_Forms.jpg
Views: 3671
Size:  206.7 KB

Name:  Scupper_Tube_Mini_Deck.jpg
Views: 3660
Size:  190.0 KB

Name:  Scupper_Tube_Transom.jpg
Views: 3693
Size:  204.4 KB

Name:  Mini_Stringer:Deck_Extention_S.jpg
Views: 3679
Size:  215.6 KB

Name:  Scuppers_Boxed_In.jpg
Views: 3638
Size:  188.0 KB
Old 09-28-2017, 12:13 PM
  #19  
Admirals Club Admiral's Club Member
Thread Starter
 
Join Date: May 2015
Posts: 947
Received 351 Likes on 201 Posts
Default

I used some 1/2" foam to back up the coamings forward. Then I used leftover carbon core to make the aft gunwales.

Name:  Coaming_Backing_Foam.JPG
Views: 3647
Size:  210.6 KB

Name:  Coaming_Fair_Curve.jpg
Views: 3635
Size:  105.3 KB
Old 09-28-2017, 12:14 PM
  #20  
Admirals Club Admiral's Club Member
 
Join Date: Jul 2011
Location: Sarasota, Fl
Posts: 2,123
Received 306 Likes on 206 Posts
Default

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?

Thread Tools
Search this Thread

Contact Us - Archive - Advertising - Cookie Policy - Privacy Statement - Terms of Service - Do Not Sell My Personal Information

Copyright © 2018 MH Sub I, LLC dba Internet Brands. All rights reserved. Use of this site indicates your consent to the Terms of Use.