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Materials I used to rebuild a 21' center console

Old 06-11-2019, 04:06 PM
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Default Materials I used to rebuild a 21' center console

I've asked a few questions and found tons of helpful info here while rebuilding my 21 ft kencraft. It's an older carolina style bay boat similar to the privateers and parkers. Not the deep v challenger. I never found a list of materials anyone posted on line to figure a budget. So like an idiot I jumped in anyways. I'm at the tail end. I still have to replace the core in the gunnel cap and gelcoat the inside. Then rig the boat. I decided to go wood free. Disclaimer I like wood. Just figured resale would be easier with composite. I enclosed the transom and made a bracket and swim platform with coosa and Pvc 80. I think PVC 80 is similar to divinicell. Thought this might help some figure a ball park budget. My gelcoat ammount is high because I'm doing inside and out. I am not an expert and may have went overkill on the glass. Anyway, here's the list.
(11) 3/4" PVC 80
(4) 3/4" coosa 26
(1) 1/2" coosa 26
(1) roll 2 oz mat
(1) roll of 17 Oz bi ax
(1) roll of 1708
(85) yards of 1708
(20) yards of 3/4 oz mat
(22) yards of 12" 1708
(55) gallons of poly resin
(2) gallons of hardener
(5) gallons of acetone
(9) pounds of fumed silica
(15) gallons of gelcoat
(3) quarts of wax
(2) quarts of pigment
(4) gallons of epoxy resin
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Old 06-11-2019, 07:31 PM
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First off, thanks for that comprehensive list....second holy crap that's a lot of materials in that list. Any links to posted progression of your project? Sounds cool .
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Old 06-11-2019, 09:52 PM
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55 gallons of resin? Jesus, I hope it doesn't take that much on my 18'. First, it'd take two years to afford it, and second that's 500 lbs of just resin.
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Old 06-12-2019, 05:58 AM
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That's entirely believable and a good illustration of the differences in composite vs. "traditional" construction. Plywood by itself has more structural strength than the foams and honeycombs which rely on the glass skins. Even with the additional resin/glass the same panel can still be lighter than plywood.

It's a trade off, like everything in boat construction. Weight, cost, effort, longevity, you have to choose what's more important to you.

I could further complicate the equation by bringing epoxy into the variable list. Epoxy is about 3-4 times as expensive per gallon but its physical properties allow much less glass to be used, reducing the total amount needed and the finished weight. Decisions, decisions!
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Old 06-12-2019, 06:45 AM
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Originally Posted by bills106 View Post
...Plywood by itself has more structural strength than the foams and honeycombs which rely on the glass skins....I could further complicate the equation by bringing epoxy into the variable list. Epoxy is about 3-4 times as expensive per gallon but its physical properties allow much less glass to be used, reducing the total amount needed and the finished weight. Decisions, decisions!
Yeah, found that out on Epoxy cost, as I started my project in epoxy because I already (somewhat) knew about mixing and using it, and plywood because Coosa was WAY over budget on my first build to learn what I'm doing. So what IS the difference in layering say, a stringer, when using plywood v. foam. And I'm sure that Coosa 26 would take less than say Divinicell.

And yeah, Ducknut, let's see some pics!
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Old 06-12-2019, 08:16 AM
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I blacked out for a minute there reading that list. I am in the beginnings of doing a 20' SeaCraft and have been in the middle of a lot of these decisions. What to use and where. At the stringer stage at the moment and decided to use two part foam to act as molds to raise the deck. I built a 4 ft. mold out of SeaBoard that I got cheap and poured a bunch of foam forms the size and height I needed for my stringers. The only additional thing I might add to Bills list is time. Waiting on the materials to show up, taking the time to make sure you think it through....it all adds up to more and more time. I have spent too much time thinking about what to use and where than actually doing the work because this isn't cheap and we all want it done right.

Would love to see how you enclosed the transom. I am trying to find a simple design to fix mine. As part of that, in the end I am using CarbonCore for my deck replacement and composites where it makes sense to keep weight down. So....you know...mine doesn't look tippy.
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Old 06-12-2019, 08:46 AM
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If you look thru the OP recent threads. None have pictures or any substance. Neither does this one. The material list is IMHO 50% too much. I'm doing a sisu cabin boat completely done over and I've only needed half what he ordered
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Old 06-12-2019, 07:32 PM
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Originally Posted by Fordy View Post
If you look thru the OP recent threads. None have pictures or any substance. Neither does this one. The material list is IMHO 50% too much. I'm doing a sisu cabin boat completely done over and I've only needed half what he ordered
well that's helpful. I took the time to put my material list together to give someone a ball park idea of materials for rebuilding a 21 ft. Something I couldn't find anywhere online after a lot of searching.
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Old 06-12-2019, 07:47 PM
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I don't post much on any forums so I don't know how to upload pictures. I'll try to put some context to this. It might appear like an excessive amount of materials, but building the rear gunnel, filling in the notched transom, building a console, and bracket with swim platform eats alot of extra than the standard rebuild. The transom is (2) 3/4" coosa. Layer of csm, 1700, 1700,1708, 1708, 1708, 1708. The stringers are 3/4" coosa. Csm, 1700, 1700, 1700, 1700, 1700, 1708. The floor is 3/4" H 80. Bottom is CSM, 1700, 1700. Top is (3) layers of 1708. The rest of the materials went to the gunnel, filling in the transom, console, bracket, and soon to rebuking the gunnel cap. I did use some of the materials to rebuild the casting platform on the skiff. Hope this puts a little context to the list
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Old 06-12-2019, 07:59 PM
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Originally Posted by Ducknut View Post
I don't post much on any forums so I don't know how to upload pictures. I'll try to put some context to this. It might appear like an excessive amount of materials, but building the rear gunnel, filling in the notched transom, building a console, and bracket with swim platform eats alot of extra than the standard rebuild. The transom is (2) 3/4" coosa. Layer of csm, 1700, 1700,1708, 1708, 1708, 1708. The stringers are 3/4" coosa. Csm, 1700, 1700, 1700, 1700, 1700, 1708. The floor is 3/4" H 80. Bottom is CSM, 1700, 1700. Top is (3) layers of 1708. The rest of the materials went to the gunnel, filling in the transom, console, bracket, and soon to rebuking the gunnel cap. I did use some of the materials to rebuild the casting platform on the skiff. Hope this puts a little context to the list
Dont let the wannabes detract from your informative summary Ducknut, while o think you massively overbuilt some areas, you weren't that far off in the big picture. Many just have no idea what it takes, and the materials are just one third of the project when you factor on labor at a rate far below any other trade.
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Old 06-12-2019, 08:23 PM
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Originally Posted by bills106 View Post
Dont let the wannabes detract from your informative summary Ducknut, while o think you massively overbuilt some areas, you weren't that far off in the big picture. Many just have no idea what it takes, and the materials are just one third of the project when you factor on labor at a rate far below any other trade.
Appreciate it. Your probably right. I'm no expert. This is by no means the only way to do it. I just kept coming to the conclusion I only want to do this once, might as well make sure it's strong. One thing I kept reading was try to match the factory glass thickness. The floor was tore out when I bought the boat so I don't know what they used. Even as much glass as I through at the boat I never matched the factory thickness. Close but not as thick as the factory. I'll see if I can figure out how to post pictures. Not enough hours in the day.
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Old 06-12-2019, 08:26 PM
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Originally Posted by Ducknut View Post
... I'll see if I can figure out how to post pictures. Not enough hours in the day.
Sent you a PM on that.

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Old 06-12-2019, 08:41 PM
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Originally Posted by Fordy View Post
If you look thru the OP recent threads. None have pictures or any substance. Neither does this one. The material list is IMHO 50% too much. I'm doing a sisu cabin boat completely done over and I've only needed half what he ordered

I looked through your posts back to April. Should I criticize you for all the bullshit answers, general inaccuracies or unhelpful responses you so graciously provide? If your build is as accurate as the rest of your answers I would say your half helpful at best, so your 50% to little.


I'm sure I don't want to try to figure out the material list for my project. I think one of the big variables in supplies is how extensive you want to get and how much you truly build versus source that someone else built. Ie doors, gutters, hatches - if you purchase or can reuse the old floor/liner or build your own. How about fish boxes, livewells, build a new cap versus reusing the old. To just do a transom and stringers and a flat floor is significantly less than quite a few of the other builds.
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Old 06-13-2019, 03:45 AM
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I think you forgot the uni directional cloth in your list.
Having just wrapped up a 17 build and starting a 25 I can easily see your list as ligit and good for someone who is considering doing a complete build to consider. I was amazed every time I needed to order another 5 gallons of epoxy.
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Old 06-13-2019, 09:52 AM
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you missed paper, tape ,grinding discs , resin cups. chip brushes, acetone .................................... Until you've done it , you cant imagine the cost
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Old 06-13-2019, 05:29 PM
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I have a mountain of lowes receipts for the brushes, rollers, tape, respirators, grinding wheels, sandpaper, mixing cups. I won't add those up. Too depressing. I'll just say it's a significant ammount of the total build cost. I appreciate all the feedback. I hope that others that considering a rebuild would be able to find this thread. I initially budgeted $3000 for the total rebuild including the tank. I blew through that pretty quickly.
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Old 06-13-2019, 05:59 PM
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Originally Posted by Ducknut View Post
I have a mountain of lowes receipts for the brushes, rollers, tape, respirators, grinding wheels, sandpaper, mixing cups. I won't add those up. Too depressing. I'll just say it's a significant ammount of the total build cost. I appreciate all the feedback. I hope that others that considering a rebuild would be able to find this thread. I initially budgeted $3000 for the total rebuild including the tank. I blew through that pretty quickly.
Buying things in bulk is certainly the way to go. Any of the consumables you think you need, it seems you need twice as many. But mixing cups by the hundred on Amazon, 50 packs of chip brushes, I can't remember the packs of the hot dog rollers but can get them cheaper on Amazon as well. And supplies you can buy in bulk and have shipped freight on a pallet is tons cheaper, just have to plan ahead.
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Old 06-13-2019, 06:14 PM
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I will also confirm that list sounds about right. I don't even have the deck down on my Mako yet and have blown through 30 gallons of resin.

I will also second buying consumables either on Amazon or at Harbor Freight.
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Old 06-15-2019, 07:31 PM
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I used 120 gallons of poly and vinylester resin on my kencraft. I’m sure you’ll be buying more when all said and done

Last edited by cummins28; 06-15-2019 at 07:39 PM.
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Old 06-16-2019, 03:16 AM
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And people want to know why boats cost so much. Thanks for the list, I think I will go buy a new boat.
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