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1987 Harris Flotebote 240 Classic Restoration

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gerard143 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gerard143 Quote  Post ReplyReply Direct Link To This Post Posted: 05/29/2018 at 2:22pm
Well I did some cleanup on the outboard.
Thru all my trials and tribulations so far I’ve found my 10 year old bottles of DuPont gel spa cleaner (mix of acids) works the best and cleaning the aluminum. I’ve also tried pink (hydroflouric acid) and the alkaline yellow coil cleaners along with toonbrite. Those don’t work that well and turn the stuff whitish gray.   The gel is great because it really clings and doesn’t dry out and leave streaks.   What sucks is it’s no longer made. So once my stash is gone that’s it. Too bad.

Anyways the gel took off all the brown and then I spray bombed the motor quick with Johnson paint. What a diff wow!!! Such little work and such huge results. Only thing left is to clean the paint off the anode.

I also bought a 2007 etec 115 so I’ll be selling this motor complete with controls, cables and steering helm. The motor is a runner.

Here’s some pics of before and after on motor.









Edited by gerard143 - 05/29/2018 at 2:29pm
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Some new wood on the way. Gonna get this baby moving along again.

Back to being excited. Placed an order for tons of underseat lights with more orders to follow. I want to do a full exterior lightning kit as well.

Pontoonstuff has been such a help with issues. Can’t recommend these guys and gals enough!

Edited by gerard143 - 05/29/2018 at 5:11pm
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updates, old motor is off and sold along with all the cables, harness and controls.  got 2 grand for it.   

Gotta get working on the deck again and build a new piece of transom wood. 


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Post Options Post Options   Thanks (0) Thanks(0)   Quote gerard143 Quote  Post ReplyReply Direct Link To This Post Posted: 06/14/2018 at 10:15pm
Well tons of updates since my last post.   

Been learning a lot of things along the way.  First off the bad....
1. When you order new aluminum good luck getting mint pieces with no marks on them.  Thats been my experience.
2.  A good 75% of every single thing i've ordered new for this project comes damaged. From a binnacle, to docking lights, to wood, to aluminum, to seat pedestals and more.  I even get brand new items from BRP that are boxed wrong (set of gauges).   I have spent so much time dealing with returns and trying to get new products sent out its ridiculous.   Right now I am tracking 7 return orders.   The marine industry really needs to get some quality control standards in check.   
3. Some things are incredibly hard to find.  
4. People want way too much for a custom snap on cover, replacing bimini top covers and an insane amount for the clear window enclosures for the cockpit area.  
5. Learned that my rails are anodized as is most of the alum on boats.  
6. Learned that most cleaning products ruin my rails look along with the acid wash and coil cleaners everyone recommends.
7. Plus a lot of what not to do like use acid on rails lol. Along with foaming degreaser bad idea, grill cleaner bad idea, simple green bad idea, wheel cleaner possible acceptable.   All this stuff just turns my rails white and cloudy and I can't even buff it  off.  Which led me to a new decision on these rails.  Keep reading. 

Now some of the good.   

1. As mentioned I bought a much newer motor, the old one sold within a day for 2 grand, so $2750 into the newer motor.   Not bad at all for a 14 year upgrade and to Direct Injection from carb plus another 25 horse.  
2. The replacement decking is down, I filled again and sanded.  I busted out my orbital sander and hit some seams to help smooth the difference in height between some joints.   Figure prep is everything before I laid the woven vinyl and aqua tread flooring.
3. This time I decided on rolling out the flooring glue versus troweling. After watching more videos I figured this way allows for a more even consistent application and would go faster. Less wear and tear on my knees and back too.  I tell ya though this stuff dries way too fast though. The wood seems to suck it up fast which speeds up that drying time and thins the coat out so I went over it all at least twice with glue.   It was difficult with the fast drying time even doing smaller areas like two 4x8's at a time.  Temp was 70s so not too hot.  I seem to have decent bonding but it probably could have been better in a couple areas.  All in all though it seems pretty nice overall.
4. The woven vinyl and aqua tread came out great.   The woven vinyl is tougher to apply without bubbles as its so much more flexible and stretchy.   Here is what I recommend after doing this to anyone who wants to lay the vinyl.   
  • Shoot for a cool day with clouds not bright sun to slow dry times. 
  • I recommend renting a 75lb flooring roller.   This part i feel is critical.  I paid $16 for a weekend  rental at taylor rental up the road from me.  
  •  Do a trial run BEFORE the glue is down. Lay the material out and run the roller over it.  This is what made all the difference in my job on the woven vinyl.  My vinyl had tons of areas of bubbles etc that didnt look pretty. The GF said to me, run the roller over it before we glue it.  I did and wow the stuff looked awesome. So we folded half back, applied glue and laid it down.  It wasn't bad at all but needed some bubbles removed. 
  • Tried the roller AFTER glue was down.  Don't recommend that for the woven vinyl.  I recommend using a plastic board with smooth rounded edges like a cutting board and working the bubbles out by sliding that at an angle away from you.  Works great.
  • As recommended don't glue more then half the boat at a time.  Maybe a 1/3 at a time.  Make sure when starting to glue the next section after you do the first to use a paint brush and hit the decking good right at the edge where the prior glue ended.
  • Aquatread doesn't need the roller before the glue.  Just lay it, run the roller and you are done.  Very easy getting that stuff to lay smooth with no bubbles. 
5.  Installed a new winch post of my trailer.  It's setup so it can accommodate a third pontoon for future planning plus it has a built in ladder and grab bar.  This thing was so worth the $300.  Magic tilt makes it. So easy to walk up onto the boat now when its on the trailer. 

6.  Took awhile but came up with a solution (thanks to thehulltruth.com forums) to replace my 1.75" thick transom wood piece that the motor bolts too.  I used a piece of LVL lumber.  Cost me $9.78 for a 3 foot piece of it 16" wide.    I traced the old one, cut the new one and done deal.     
7.  After working with my rails and being unsuccessful cleaning them up without damaged them (anything other then soap and water,which didn't clean some crudded up areas well enough) I ultimately decided to take my right angle grinder and throw a 3m Bristle Disc on it and clean up all the scratches on them (hundreds and hundreds from 30 years of abuse) then send them out to be powder coated.  Overall i guess this was the best solution for reviving these rails.  Re-anodizing just isn't very practical. Me painting them with automotive paint is probably a $350 investment in materials and is a lot of work.  Plus durability is a concern.  So ultimately I met with a local powder coater.  Saw his operation, the color sample, we discussed the thorough prep job beforehand that he will do (sandblasting, phosphate cleaning, etc) and some other details.   Cost is coming in at $700 bucks.  The rails should look nice when done and with about 2,000 less scratches then they had after my sanding.   3 of the big rail sections left to do.  Taking me about 2 hours a rail easy but fabulous results removing scratches with those 3m discs i mentioned.  Hopefully when I re-skin them after with my alum sheeting I don't damage the coating. Hoping long term it holds up ok and doesn't flake/chip off due to bad adhesion anywhere.  The risk is always there with a coated surface but overall it's my best option i feel.  I just wouldn't be happy with how the rails looked. Everything else will look new and these rails would have looked old and dingy still. 

8. Figuring out how to fill in the section of missing rail where the recessed motor area use to be has been a challenge.  I have to correlate it all with the powder coated so those get covered too.  I was going to weld them in but then my back rails are one giant piece 90 inches wide and thats too hard to transport and for him to coat probably.  So then I said ok I can weld tabs and just screw to existing rails, but the top area proved challenging for a clean look.  Then I came up with the genius idea of using tubing connections to cover up the seam where the two rails butt right up at the top.  So thats where I stand on those.  Trying to find some plastic connectors the right size, i cut my tube to length, he can coat them with all the rest, i assemble later quickly with the connectors.  No real delays.  



Here is a photo of my new winch post with integrated ladder.  This mod was so worth the $ and I absolutely love this thing.  Such good quality and super handy!!!


Here is my old transom wood piece.  Wasn't in too bad of shape for 30 year old wood. The edges of the right bolt holes were all cracked though.  They drilled too close to the edge.


This piece of wood was a lifesaver.  I was really struggling to find a good easy solution to this 1.75 wide wood that was about 15" wide.  I had a post on thehulltruth.com forums for about 2 weeks before a gentlemen recommend using an "LVL".  $9 later and a few cuts and I have my wood and since its laminated layers like plywood it's stronger then the original transom piece. 


Here it is all cut laying over the old one. 


Here is a shot of the Infinity Luxury Color #10 woven vinyl flooring. 


Here is the infinity woven vinyl and aquatread weather slant teak with lines flooring.  It was actually pretty easy to get that cut perfect.   With just the woven vinyl down in put the rails where they belong.  Then I traced the front edge with a sharpie onto the vinyl.  Then I removed the rails and then I made a new mark about .6 inches starboard of the original line.  This put the line right in the middle of the rails.  I cut the material out in one piece, then layed that cut edge over the aqua tread and cut the exact same pattern.   It worked very well! 


Here is how it looks without the edging back on but the rails in place. 


Here is a closeup shot with the edging on.  I still haven't laid down the trim piece under the front gate where the two pieces of material meet.  I need to order some satin aluminum T molding (for floor transitions).

Here I am using my right angle grinder with 3M bristle discs on there cleaning up the 50 million marks and scratches and nicks on the rails.   This process sucks.  I already have about 25 hours invested in it.  One rail and a gate left, thank god.  Can't wait until its done. 


Here is some aluminum satin anodized pontoon railing.  This stuff was so hard to find which surprised me.  I had to order 24 feet when I only needed 8.  Got it from csctextiles.com, it is .062 (1/16 basically) not .090 like my rails but for what I need it for it'll be fine.  It looks pretty wish all my rails still looked like new alum lol.  



And lastly here is a picture of the powdercoating color he has that is close to the rails natural anodized color.   





Edited by gerard143 - 06/16/2018 at 3:28am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 06/15/2018 at 5:36pm
Awesome stuff! use "image resizer for windows" you can edit multiples at once and keep originals. Edit your post there is a checkbox for notifications.
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Originally posted by curtiscapk curtiscapk wrote:

Awesome stuff! use "image resizer for windows" you can edit multiples at once and keep originals. Edit your post there is a checkbox for notifications.

I used to use that or similar then it stopped working.  I'll have to try again.   Also I can't find anywhere to add the notifications.   Edit first post and looked all over but no notifications??

Update- installed image resizer. working well. 

Also added pictures to my prior post.   Got some new aluminum edging today for the front and back of the decking.  Didn't open it yet.  Hoping its in mint shape and does the job I am hoping I want it to do. 




Edited by gerard143 - 06/16/2018 at 3:09am
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Sanded 1 rail and 2 gates today. 7.5 hours and still not done. Craziness lol.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 06/18/2018 at 6:55pm
Email notification is there now!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gerard143 Quote  Post ReplyReply Direct Link To This Post Posted: 06/19/2018 at 3:24am
Originally posted by curtiscapk curtiscapk wrote:

Email notification is there now!

awesome!   We need to get that feature enabled for everyone then things would be more active on here I bet :-)


Edited by gerard143 - 06/19/2018 at 3:25am
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It's there for everyone now.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gerard143 Quote  Post ReplyReply Direct Link To This Post Posted: 06/20/2018 at 10:33pm
Well my rails are off to the powder coating.   Spent about 40 hours sanding all the nicks and scratches out of them.   Amazing once I got going on it how many marks from the last 30 years.     A monsoon rain storm hit right as we were trying to load them all in the truck and protect all the corners with cardboard taped on there to prevent damage.   I told the powder coater guy please be super careful with these, i spent 40 hours sanding them making them mint.  A minute later he drops one of the big rails right over in the storage rack.  I was thinking in my head seriously dude lol. 

Anyways praying they turn out good.

In other news, the deck edging came to replace my front and rear deck trim.  Photos showed it as smooth on both sides, what arrived was ribbed on one side. Other then a couple small blemishes it came in good shape.  I guess it will have to do with the ribbed front, suppose it'll hide scratches better.  I notice in the rear it will hit the transom so I am shimming the transom down with some alum flat stock.  3/8 in the rear which equates to 1/8 shim in the middle.   

My replacement binnacle came and its much nicer then the first damaged one I got.   I wish I could say my replacement springfield seat pedestal came in great shape the second time around but this one is damaged even worse.   The cylinder is scratched all over and gouges in the alum.  Lame.   




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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 06/21/2018 at 2:25pm
Originally posted by gerard143 gerard143 wrote:

   I wish I could say my replacement springfield seat pedestal came in great shape the second time around but this one is damaged even worse.   The cylinder is scratched all over and gouges in the alum.  Lame.   



from pontoonstuff?
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No sir.   From carid.com, one came from land and sea the big disturb, second one from Kellogg marine.   Boxes come fine. No damage. But pedestals inside are beat up a bit.   Believe they are coming right out of Springfield this way.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gerard143 Quote  Post ReplyReply Direct Link To This Post Posted: 06/30/2018 at 8:56pm
got my rails back monday.   7 of them needed re-work.   Some thin spots were primer was showing right thru, a couple scrapes they did in the primer coat then topcoated i had to sand out and some serious grit they got on an edge.  

So loaded them back up and dropped them off tues.  Lame.   I worry about adhesion now between coats. Hope to god these things wind up right this time. 

Missing half of boating season.

Its mid 90s all week so work is tough out there but im plugging away.   The transom board is painted and ready to go.  I'm sanding down then polishing up the transom trying to take 30 years of age out of it.   Sander blew apart mid way.   Just bought a new porter cable model that will 6000 rpm if I want.  The thing is a dream to use.   So smooth.  

I made some cutouts in my dash for the binnacle and carefully made some mods to be able to fit a 7" raymarine axiom touch panel in my dash that wasn't made for a 7" screen lol.   It turned out nice.   Couldn't center it dead nuts perfect due to a 2" gauge close to it but nonetheless its pretty pimp.  

This thing has netflix on it and can control a dji drone from it.  These axiom MFD's are pretty sweet.  It's got me excited. 

Also having new wire marine work some magic for me on some custom switch panels and some other panels for the dash area. 

thats the update!
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Clap
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The powder coater used primer?

I have never seen that before, he should of told you that the small nicks and scratches would be filled in with the powder coat?

Can't wait to see pictures
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Well I want good adhesion.  Epoxy primer is the way to go, then a UV resistant super durable polyester topcoat.  https://www.nortekpowder.com/tds/S6SA62.pdf     Also didn't want to take my chances with nicks, scratches, dings showing thru the primer.  Prep is everything.  



Here are some pics of the polished transom, my 7” ray marine mfd test fit in the dash panel cutout I made and some photos of the rail blemishes I’m having reworked.

-update, rails are done.  Hoping round 2 is better then round one.  

 


Edited by gerard143 - 07/03/2018 at 8:50pm
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Well for the most part the rails are ok except for one.   It came out pretty bad. Lots of orange peel look with all the dips being white versus gray.   It honestly needs to be stripped now and completely redone. So that sucks.

Started putting paneling in.    My god this blue looks amazing with the silver. This boats gonna be so pretty.







Edited by gerard143 - 07/04/2018 at 2:02pm
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That Blue is sweet! Keep em coming!
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Welll I’ve progressed a good bit.   My third seat pedestal is good enough. One small mark but I can deal with it.   I had another roll of 20’ of paneling sent from fenceforpontoons because about 20’ of my 60’ roll was waste as it had bends, dents and plastic backing was scored thru in some areas and scratched panel.   The replacement roll was dented in several areas so I was only able to use enough for 3 gate pieces. Still need another good piece about 7 feet long.

The paneling was challenging to install (I’m a perfectionist, one little mark and I’d toss the piece) but in the end it came out great. Def the worst part of the remodel dealing with those rails and fencing.    I opted not to use shears as I didn’t like the bends it leaves every time you squeeze. I used my grinder with a cutout wheel.   I think it would look nice on the outside with paneling covering up the top open area of rails but on the inside it would look bad. I’d have to screw or rivet it all in and opted against it.   It is what it is.

Still have to strip down my one rail and have it coated again.

Here are some pics:
(Pics coming this evening)




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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 07/10/2018 at 4:10pm
Can't wait!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote m and m Quote  Post ReplyReply Direct Link To This Post Posted: 07/11/2018 at 3:31am
build is looking great!  Keep up the good work.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote gerard143 Quote  Post ReplyReply Direct Link To This Post Posted: 07/12/2018 at 8:43pm
Here are some of the promised pics.

As for updates.... I have my one rail that I didn't like the powder coat one mostly stripped.   Can't wait to get that fixed and finish my paneling.   


Some shots of the blue paneling:



Couldn't believe it but I found the exact same corner caps as my 31 year old ones.  Pontoon specialists had them.



Here is a shot of the paneling installed.  I ultimately went the same way it originally came as far as no paneling in the upper section of most of the rails.   On the outside it would look awesome with paneling to the top rail, however on the inside it would look ugly in the areas it would be exposed.  Too many rivets, screws, etc.   Plus I just got tired of dealing with the rails and paneling.   It's going to be august soon.  I just want to move the project along and get on the water. 


Here is a shot of the two flooring pieces and the transition strip I installed that goes between the two front railings in the gate area.  Looks awesome. Plus a little dyson action going on here, lol. 


So this is the rear area that is now straight.  Used to be cutout for recessed motor area.   The downside if I left it recessed is the newer motors you can't trim up all the way. It would hit as they are taller.   So the upside is I now have a lot more storage area which i love.   I plan to fill in this area with paneling and rails.  I'm not there yet. 


The silver I did for some contrast, in person it is metallic and looks sharp.  The pontoons themselves look awful.  I plan to sand and polish them up to a mirror finish. 


Some of the front seats installed. 
\

Here is my seat layout, at this point they weren't bolted in.   I notice for some reason the pontoon stuff leanback's vinyl is a slightly different color light grey then all the other seats. Both leanbacks came this way.  It almost seems a bit beige.  Not sure why that is.  You can notice it good in the photo above.  Look at where the two cushions mate up, ones gray, ones beige looking. 




Here is a before and after shot comparing the work i've done so far to the old setup.  Quite a diff aye?

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Looks Awesome! send close up shots of you cushions to support!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote gerard143 Quote  Post ReplyReply Direct Link To This Post Posted: 08/19/2018 at 3:49am
boy do i have some updates for you boys and girls.   

I need to get some new photos up!
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Joined: 01/30/2013
Location: OP KS \Truman
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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 08/22/2018 at 4:19pm
Let's see em!
Craig n Paula
THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake
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