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1988 dusky 25 6 rebuild

Old 01-04-2021, 02:00 PM
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Default 1988 dusky 25 6 rebuild

Hello again everyone. This is my second forum start of a 1988 dusky 25 6 or 28 if you count the dusky drive. I have another forum on here about a 1972 20 dusky thats a ground up rebuild that Im in the process of as well. Plans for this build is to replace the transom with coosa board, rebuild 2-3ft of rear stringers with coosa, get rid of forward cabin and repaint the entire boat with a new t top. Trying to keep it simple haha!



Ugly forward cabin. The top deck has plenty of glass to just drop it straight to the floor.

Tiny pie plate. I always wonder how people can work out of those things. I believe in having plenty of room with a floor hatch to not cuss yourself out while fixing stuff.

T top is raggedy
Old 01-04-2021, 03:17 PM
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id be curious what the stringers look like once you open her up
Old 01-06-2021, 01:17 PM
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Funny how my other dusky (1972 20 dusky) taught me soooo much about a project and easier ways of going about things. Opened up the transom, grinded down just about everything I wanted, removed through hulls but dont have pictures of it yet. There was a very shotty repair done the the hull side. Its like somebody packed play dough in and used bondo to fair it in with a crappy glass job to add on. I patched it with 3 layers of 1808 first let that kick, scuffed it with 80 grit and threw two more layers of 1808 with a third layer of CSM to tie it all in. After all of it kicks off Im going to grind the outside and throw 2 layers of 1808 on the hull side and fair it all back in. Im also going to patch up both through hull holes and upgrade to a 1 scoop through hull attached to a 3 outlet manifold for a washdown, livewell, and extra. Getting the dusky drive off was ROUGH but it needed to be done for me to be satisfied. I have a friend who is going to make me a 1/4 sheet of aluminum backing plate for the dusky drive which will go inside the hull. As for the stringers, they werent even connected to the transom, the starboard side is pretty good. Im gonna resin coat where it is exposed to seal it off from the elements. The port side is slightly rotted I cut back to good wood and will rcoat that with stop-rot by fascist probably 3-4 coats to really seal it in. The new stringer ends will be made out of coosa board.

Small hole to get an idea of whats goin on



Only a couple splotches of some kind of epoxy putty holding the liner in place...


Little rot

Whoever did last transom job had an entire sheet nearly delaminated. No Bueno but cut down on my grinding substantially



This took me ALL DAY to remove.

Stringers arent even connected to transom... deceleration hoses ruining integrity and were never sealed properly.





Pretty in pink.

3 layers of 1808 kicked before 2 more layers of 1808 with a layer of CSM to tie it all in.
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Old 01-08-2021, 06:59 AM
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I owned 2 Dusky's and was lucky to only need the hatches replaced. I commend your dedication, I couldn't do it.
Old 01-23-2021, 07:28 PM
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Boats been moving slow. Been having some trouble with the title process so havent been too keen on going crazy yet. Did buy the coosa board and make a template of the transom so I have that at the ready. Also got the outside of the hull glassed where that bad repair was. Made a MESS of epoxy on the hull side but I gotta sand it all down anyway

Old 01-23-2021, 07:42 PM
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I had a buddy have issues with a boat title. He saved all his receipts from the full rebuild and had it titled as homemade. Just something to think about.
Old 01-24-2021, 07:15 AM
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Originally Posted by Mailbox View Post
Boats been moving slow. Been having some trouble with the title process so havent been too keen on going crazy yet. Did buy the coosa board and make a template of the transom so I have that at the ready. Also got the outside of the hull glassed where that bad repair was. Made a MESS of epoxy on the hull side but I gotta sand it all down anyway

Masking paper and tape are your friend. One spot of sanding isn't too bad but multiply that over several repairs and you're blowing through time and sandpaper at an alarming rate.
Old 01-26-2021, 06:07 PM
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Looks similar to what I am dealing with. I think your ransom was original, as it looked a lot like mine did. My transom and stringers were/are full of termites. I didn't plan on doing the stringers, but I need to. I am all in. Just bought eight sheets of Coosa for stringers and floor. Hope it is enough. Good luck, I will be watching your project. I am in the Tampa area.

Old 01-27-2021, 07:03 PM
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I'd add a second set up stringers while you're doing all this work. Two stringers was not enough for them
Old 01-31-2021, 04:31 PM
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Originally Posted by MrMakeItWorse View Post
Looks similar to what I am dealing with. I think your ransom was original, as it looked a lot like mine did. My transom and stringers were/are full of termites. I didn't plan on doing the stringers, but I need to. I am all in. Just bought eight sheets of Coosa for stringers and floor. Hope it is enough. Good luck, I will be watching your project. I am in the Tampa area.
dang. Luckily mine dont have termites. Luckily its been dry the last few weeks and gave them a chance to dry up. Gonna stick a fan on them for a day or two and dig out at much wood as I can. Unfortunately/fortunately Im a college kid (studying naval architecture/ocean engineering) and can only manage to afford one sheet of 1.5 coosa. You are the man doing it right with coosa stringers. Good luck with yours!
Old 01-31-2021, 04:32 PM
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Originally Posted by Team Seaside View Post
I'd add a second set up stringers while you're doing all this work. Two stringers was not enough for them
by that do you mean putting them on the outboard side?
Old 01-31-2021, 05:10 PM
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Here is where I am adding them. I can only get from transom to 10 feet up before it starts curving, so I am only going 10 feet, then I will add a bulkhead at the end of it tying it in to the original stringer and the side of the hull. That's how I am doing it, others will comment.
Old 02-01-2021, 01:15 PM
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got the area cleaned up some more, cut the floor and stringers back a little more. Got the coosa cutout with a tolerance of +- 2mm. Gonna get glued in wednesday



Old 02-01-2021, 01:17 PM
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nice work!
Old 02-02-2021, 03:14 PM
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made some big clamps out of 2x4s dont know what type to call them but when you tighten that middle screw it tightens the hell out of the bottom section of it. Then I have a 2x4 going the length of the transom for the mid section that are getting 5/16 lag screws with fender washers coming from the coosa side of the transom. Then I am using clamps on the very top section for the top obviously. Feel like I need more clamps can never have enough! Coosa is prepped out just needs a wipe with denatured before it goes in. Got to use my favorite tool the router tm throw a nice round over edge on the top side to have a much easier time with the glass when that time comes. Gonna mix cabosil up and spread it over the entire transom area between 1/8 and 1/4 thick and also glob up all the corners. Then throw a good radius around the inside more pictures to come!


Old 02-02-2021, 04:18 PM
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Very nice. A tip I was told that helped out was to drill a handful of holes (I did 1/4") throughout the coosa to allow air to escape once the core is placed in the transom as you are tightening down the clamps. Tighten from the center out and tap with a hammer or something as you tighten your way out to help the thickened epoxy move and get the air out. All of my holes ended up weeping thickened epoxy out which I added to my filleting mix to shape around the perimeter
Old 02-02-2021, 04:29 PM
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Originally Posted by Floatingalong View Post
Very nice. A tip I was told that helped out was to drill a handful of holes (I did 1/4") throughout the coosa to allow air to escape once the core is placed in the transom as you are tightening down the clamps. Tighten from the center out and tap with a hammer or something as you tighten your way out to help the thickened epoxy move and get the air out. All of my holes ended up weeping thickened epoxy out which I added to my filleting mix to shape around the perimeter
I did just this. My other forum I have for my 1972 20ft dusky Im rebuilding from the ground up I did that and it helped a lot. I start all the way at the bottom and in the middle and work up then out evenly. The other one I did 104 through bolts and needed to find a much easier way to do it solo. This cuts the time by over half by just clamping it all extremely tight. Going to use my Milwaukee 1/2 impact
Old 02-02-2021, 04:39 PM
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Originally Posted by Mailbox View Post
I did just this. My other forum I have for my 1972 20ft dusky Im rebuilding from the ground up I did that and it helped a lot. I start all the way at the bottom and in the middle and work up then out evenly. The other one I did 104 through bolts and needed to find a much easier way to do it solo. This cuts the time by over half by just clamping it all extremely tight. Going to use my Milwaukee 1/2 impact
104 bolts to tighten? That sounds terrible! The large clamps are definitely the way to go
Old 02-02-2021, 05:22 PM
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Originally Posted by Floatingalong View Post
104 bolts to tighten? That sounds terrible! The large clamps are definitely the way to go
it was more like 50 lol but still. Not very fun when you are solo. Got covered in epoxy.
Old 02-07-2021, 11:25 AM
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transom is glued in. Have a nice radius to glass to. There was many many more clamps when it was put in, this is 30hours into the 48 hour cure process for the super slow cure epoxy I used. Quick question for anybody reading, Im wanting to put a 1/8 or 1/4in aluminum plate as a backing plate for the dusky bracket my question is if that could get glassed in ok? Not sure how glass bonds to aluminum Im using epoxy so usually sticks to just about everything it touches as long as its scuffed up correctly. Or is all that overkill? I like overkill but might be too much. Plans are to hang a 300hp on it.


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