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1991 20' Sweetwater Rebuild

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Post Options Post Options   Thanks (0) Thanks(0)   Quote LuvDLions Quote  Post ReplyReply Direct Link To This Post Posted: 02/20/2014 at 11:13am
Went home and spent 3 hours on the toon after work.  Wire brushed the front and rear cross member rails, the trim for both and the transom plate.  Installed all of the trim and put the bolts through the transom plate.  I found out my German torque specs (gootentite) don't work on stainless steel after breaking one.  Right now the 8 bolts are stainless 1/4".  I was thinking of drilling out the holes to fit some of the stainless rail mount bolts through there.  Can't hurt right?
 
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote LuvDLions Quote  Post ReplyReply Direct Link To This Post Posted: 02/20/2014 at 9:58pm
Tonight I put in the panel on the other side long rail. Tomorrow I get the last rail from the welder and start bolting them down Saturday.
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ClapClapClapStarStarStar
Craig n Paula
THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake
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Post Options Post Options   Thanks (0) Thanks(0)   Quote LuvDLions Quote  Post ReplyReply Direct Link To This Post Posted: 02/21/2014 at 1:24pm
This is the fold i was talking about at the ends to make it not sharp without molding.  Sorry these are low light, pre-dawn pictures.  They are still better than the no light, night pictures.
 
 
 
Just noticed all of the recycled coors light cans there. There must be a drunk that lives around there! Wink
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote LuvDLions Quote  Post ReplyReply Direct Link To This Post Posted: 02/21/2014 at 1:31pm
I should have cleaned the toons while it was stripped down to the rails.  Oh well, I am sure I can still giter'dun!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 02/21/2014 at 2:12pm
Just noticed all of the recycled coors light cans there. There must be a drunk that lives around there!
same as this.... but bud lite!
 
I bag all mine up and once a quarter take them in and usually get a free case with the money I get back from the recycler. this next trip may be 2 cases!
 
Craig n Paula
THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake
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Post Options Post Options   Thanks (0) Thanks(0)   Quote LuvDLions Quote  Post ReplyReply Direct Link To This Post Posted: 02/24/2014 at 11:03am
Saturday I was able to get all of the rails bolted down and the furniture put together and arranged.  I have not bolted them down yet because I think I am going to need to go back and silicone the extruded lips or I am going to have to change her name to the Rattleship! There were a few cervezas consumed on the pon Toon that night!
 
 
 
I don't think I am going to put siding in that small middle section of the front door.  Allow a little air and better vision IMO.
 
 
What do you think of those round driving lights?  Someone told me driving lights are not recommended because it meeses up your night vision and those of any other boats around.  Plus they said it may make it harder to see your navigation lights. I know, I wouldn't mind being able to see the river as I am navigationg at night.
 
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Post Options Post Options   Thanks (1) Thanks(1)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 02/24/2014 at 11:12am
that looks awesome! The lights are usually called docking lights! Only used for docking! If you had those on while navigating you would probably get stopped by the MAN! Most people use a spot light for occasional glimpses of their area at night. If you had those suckers on all the time you would only be able to see directly in front of you and be blinded everywhere else, in my opinion of course.
 
You are making quick work compared to my build. I started on 1-29 of last year and still not done all the way.Ouch
 
 
Keep up the great work! My front gate only has the middle section filled in. I am going to do just the opposite and fill in the bottom section, because of my daughters dog always wanting to jump out!
Craig n Paula
THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake
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Sunday, I was able to get the 4 fishing seats mounted and the decals put on. I guess the next step is to mount the motor, run the cables and wiring.  I need to build the box that is going to house the tanks, batteries and live well.  I am going to use one long box for the tanks and batteries along the opposite side of the back seats.  I plan on putting a piece of plywood between to seperate them, for spark/fuel vapor concerns, with individual lids.  I'll probably put some foam tape around the edges as well.  Do I need to put a vent or two in the fuel tank box section? The plan is to put carpeting on the outsides with the left over carpet and using vinyl for the lids.
 
 
The decals are not applied as well as I would have liked.  I didn't use enough soapy water and I have a ton of air bubbles.  You can only see them when you get close.  I guess that is fine, because I beat the crud out of the new siding which you can see in the picture too.  Ugh!!!  Next time, i do not used the extruded lip, I will just screw it or rivet it down instead.  That crud is a pain!!!
 
 
Oh yea.  I still need to clean the toons.
 
I plan to be on the water sometime next month!!!!  Fingers crossed.
 
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Post Options Post Options   Thanks (1) Thanks(1)   Quote SunBlocker Quote  Post ReplyReply Direct Link To This Post Posted: 02/24/2014 at 11:33am
Like Craig said... the docking lights are to only be used during DOCKING!!  Not while underway.

In my area running with your docking lights on is technically illegal... but sadly it is not properly enforced.  And I wish it was.  We have way too many folks who treat them like headlights at night and they are a true hazard!


Edited by SunBlocker - 02/24/2014 at 11:33am
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Going to place an order today from pontoonstuff.com as well.  I need to order some matching vinyl and the aluminum corner caps.  After all of this work the old rubber ones just don't look right!
 
It's only money right?
 
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Originally posted by SunBlocker SunBlocker wrote:

Like Craig said... the docking lights are to only be used during DOCKING!!  Not while underway.

In my area running with your docking lights on is technically illegal... but sadly it is not properly enforced.  And I wish it was.  We have way too many folks who treat them like headlights at night and they are a true hazard!
 
Thank you both for that info.  I guess, I will just use some standard "docking" lights then. That's why I asked all you knowledgable folks!
 
I was also planning to use them if we decide to do some night swimming.
 
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Last night, I had to go buy a 3-1/4" hole saw to install my steering wheel.  Then, I had to pull out the tap and die set to fix the threads I beat up trying to remove the steering wheel originally.  I laid out the pattern for the switch panels and guages as well. 
 
 
I bought 2, seasense, 5 switch with 12 volt charger panels.  More switches than I think I will need, but who knows what crazy stuff I will add in the future.  As, I was looking at the wiring, I realized what a nightmare it is going to be. 
 
The new switches come with 3, in line fuses going to 2 switches each.  So, I wouldn't need the fuse block any more and could just add 2 terminal strips, 1 for power, 1 for ground. 
 
Or, I could cut out the in line fuses and use the OEM fuse and ground panel, that way each switch gets its own fuse again and wire it from there.  The switches are power in, power out only, so all of the grounds are designed to go to the main ground terminal.  Which, for my simple mind is a lot easier as all of the jumpers on the OEM panel switches confuse the crud out of me.
 
Then, I am going to figure out how to wire the tach, volt and hour gauge. 
 
UGHHH!!!!!!!!!!! Wacko
 
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Forgot to add what switches I plan to run:
 
> Nav lights, including the white "clearance" light.
> Docking lights
> Stern lights
> 2 white, led way lights.  One up front, maybe in the front of my console and one in the rear on the end of my battery box.
> Livewell
 
These are why I need the additional 5 switch panel
> Radio, I guess, not sure if this really needs a seperate switch
> Fish finder
> Under deck, blue led's
> Under seat, blue led's.  My 6x9 speakers have built in blue led's with seperate leads and I may just use them for the under seat light, as 2 are going to be mounted in the port bench seats and two are going to be mounted in the front 2 boxes I need to build yet.  So, I am going to see if they give off enough light to meet my needs.  That is the whole reason I went with them.  The youtube videos I have found show them flickering with the bass of the music, but I think that is probably because they didn't run a seperate power source and only used the current from the speaker wire.  I guess we will find out. http://www.qualitymobilevideo.com/ts69.html
 
I could just run all the blue LED's with the way lights, or the blue under seats and under deck together, but I have the switches, so why not?
 
Can you think of any other accessories I may need switches for?
 
 
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Post Options Post Options   Thanks (1) Thanks(1)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 02/26/2014 at 11:57am
Originally posted by LuvDLions LuvDLions wrote:

Last night, I had to go buy a 3-1/4" hole saw to install my steering wheel.  Then, I had to pull out the tap and die set to fix the threads I beat up trying to remove the steering wheel originally.  I laid out the pattern for the switch panels and guages as well. 
 
 
 
I bought 2, seasense, 5 switch with 12 volt charger panels.  More switches than I think I will need, but who knows what crazy stuff I will add in the future.  As, I was looking at the wiring, I realized what a nightmare it is going to be. 
 
The new switches come with 3, in line fuses going to 2 switches each.  So, I wouldn't need the fuse block any more and could just add 2 terminal strips, 1 for power, 1 for ground. 
 
Or, I could cut out the in line fuses and use the OEM fuse and ground panel, that way each switch gets its own fuse again and wire it from there.  The switches are power in, power out only, so all of the grounds are designed to go to the main ground terminal.  Which, for my simple mind is a lot easier as all of the jumpers on the OEM panel switches confuse the crud out of me.
 
Then, I am going to figure out how to wire the tach, volt and hour gauge. 
 
UGHHH!!!!!!!!!!! Wacko
 
 
try this diagram for your switches.... no hour meter though.. It helped me a lot of course no fuse block since the switches all had breakers...... but a bus would be fine!
 
Since this question seems to come up on a fairly regular basis, figured may as well put something here.
General Instrument Wiring Diagram.
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Edited by curtiscapk - 02/26/2014 at 12:24pm
Craig n Paula
THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake
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Post Options Post Options   Thanks (0) Thanks(0)   Quote LuvDLions Quote  Post ReplyReply Direct Link To This Post Posted: 03/02/2014 at 10:08am
So, yesterday it was cold and rainy here in SoCal. I don't mind because we definitely need the rain, plus I pulled my console out and worked on it in the garage. Here is what I got done.



I still need to get a glove box to put in opposite of the radio.



I cut out a 6x16 piece of aluminum diamond plate I had lying around to make this mounting plate for the fuse block and any other accessories that need to be mounted inside the console. I didn't like the idea of screwing everything directly to the plastic on the console. I mounted it with 4 stainless bolts and nuts with a spacer between the console and plate.



Here it is all wired up and ready to go. As, you can see, everything is labeled at the fuse block and at the switches. I think I am going to get some of those rubber sleeve clamps and mount them at all 4 of the bolts to run the wires through for a cleaner finish.
Today, I am going to wire the guages and if the weather lightens up, mount the motor and run the controls, so I can figure out where I am going to mount my console and get this thing wired up. I need to get as much done this weekend, as I am going to be in Vegas next weekend. It will be the first weekend since I bought it that I haven't worked on it. I hope to have it on the water to find out if it floats by March 28th. If all goes well, we will take our first river trip of the year the next weekend for my son's 18th birthday!  Party


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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 03/02/2014 at 2:01pm
Looks awesome!
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THE FLOATER Rebuild
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22mph
OP KS
Truman Lake
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Post Options Post Options   Thanks (0) Thanks(0)   Quote LuvDLions Quote  Post ReplyReply Direct Link To This Post Posted: 03/03/2014 at 12:18pm

Thanks Curtis!

I was able to get outside between the sprinkles and figure out what wires on my OEM plug corresponded with the wires in the harness for the original lights and accessories.  Then I was able to wire that plug into my new switches and fuse block.  All the important stuff is ready to plug and play!  I will have to run new wires for my LED's under the toon as well as the speaker wires and power to the built in LED's in them. 
 
 
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 03/03/2014 at 12:49pm
That looks a heck of a lot better than mine! I need to go back in there and tidy everything up.... It is  a little hard fitting in this door thoughConfusedOuch
 
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THE FLOATER Rebuild
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OP KS
Truman Lake
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This is what my new speakers look like with the built in led's
 
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I built my battery/gas tank box last night.  Going to use the leftover carpet on the sides and get matching vinyl for the top.  Still need to build 2 for the front.  One for the bait tank and one to match on the other side for storage.  Just to make it symmetrical.
 
 
I plan to add one more piece of plywood between the tanks.  I didn't originally plan too but if I do, it will be sturdy enough to stand/sit on.
 
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Absolutely Beautiful!
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THE FLOATER Rebuild
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Not a lot to post about lately.  We went to Vegas last weekend, so I didn't get a whole lot done.  I have been working on finishing all of the boxes after work though.  I used plywood from home depot, so I am painting them with an exterior paint, hoping it will help some.  I hope to have them finished tonight so I can carpet the sides and vinyl the lids. 
 
 
I have made a list of things left to do.  Think I can finish this weekend?  I have everything I need.  I am going to call some buddies and have a "finish this damn pontoon" party!  We'll see who shows up to help and who gets to go out on it first.  Wink
 
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HELP!!!

The new motor and controls aren't long enough to reach where they need to be mounted. The control calls on the Johnson were on the right side of the motor. The mercury is on the left, too damn far away with same length (12') cables. So.... I'm stuck!  I was thinking this control with 15' cables would work. 

http://www.go2marine.com/item/253476/side-mount-remote-control-881170a3-881170a20-881170a15-881170a15.html

I was wondering if I could mount a surface style one on the left top of my console but they don't come with key switches, so I would have to try to figure that out. 


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Crisis converted! I figured out how to change the cables! Hopefully I can get them soon.
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Averted! Dang phone!
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First of all it looks great. Second sounds like your on the right track with your cables. I spent days looking for a way to hook new style steering to and old motor. hope the cables work for you.
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Almost done!
 
I plan to be on the water next Sunday to see if it floats.  I still have to upholster cushions/lids for two of the 3 boxes I built and mount the front right one. This is not a top priority as I can get it on the water without them. Top priority, is getting the speakers installed in the seat bases, so I can bolt them down, figuring out where I am going to plumb the drain for the built in cooler, so I can bolt it down and running power to the white light in the back.  Oh yeah, I need to install the registration decals yet. 
 
This is the box for my livewell.  I used 1" foam and matched the vinyl on my fishing seats rather than the vinyl on my loungers.  I have the corner piece cut but I am waiting for my cupholders to come in before i get them in.  There will be a matching box on the other side as well for storage.  I mounted the boxes to the rail and the floor, so they are STURDY! Only problem is, I went past the rail and the latch won't work anymore, but I have already formulated a plan for a new design.
 
 
 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 03/24/2014 at 12:39pm
Looks awesome!ClapClap
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THE FLOATER Rebuild
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22mph
OP KS
Truman Lake
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I also got the new control cables installed and ran to the motor which I mounted last week.  I cut a piece of diamond plate to mount to my rails for the control box.  I decided to put the back, brushed aluminum side to the outside to match the rails.  I ran the control cables, battery cables, fuel lines and steering cables, wiring harness and plug it all in.  I rtan them through nice, new, pretty shifter boots to keep some of the water out.  At the bottm of the gas/battery boxes, I used some of the seatings plastic packaging as a liner around the bottom, which already came in handy, as the tank leaked under the side handle where there was a broken weld and at the gasket for the fuel hook up.
 
 
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