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1996 Sun Tracker Rebuild

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Scott573 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scott573 Quote  Post ReplyReply Direct Link To This Post Topic: 1996 Sun Tracker Rebuild
    Posted: 08/22/2017 at 2:45am
Let me begin by saying this forum is amazing.  I've spent the last 2 days walking through each and every rebuild post...  So much great information!  

We decided a few months ago to take on a pontoon rebuild as it would be a rewarding (hopefully) experience and something that our family of 4 can enjoy for years to come.  Things got real when having a conversation with a good friend about our interests/aspirations only to find out that he had a 1996 Sun Tracker available...  Going to be a deck up re-build but why take the easy road right????

And now the journey beings.  Will try and document all as everyone else has throughout.  Appreciate any help along the way as we are fairly new to boating but can't wait to dive in.

Scott







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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 08/23/2017 at 7:07pm
Awesome neighbor! Check out my rebuild in my sig. Close to the same toon!
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 Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 08/24/2017 at 2:28am
Wow, you're right!  Jealous you're in the water but hope to be there by spring next year.  I can picture us sitting on our PS seats over the winter too!?!?!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 09/05/2017 at 11:26pm
So a very productive labor day weekend.  Was able to remove fencing, and get decking down to the condition shown below.  

Question for the forum regarding the decking: We decided to use a saw zaw and rip sections of the old decking off along each of the aluminum brackets to get better access to the existing hardware.  Have you had more success grinding off the self-tapping screws and use a little brute force to pry off?  Just trying to see what has worked for you in the past. Really appreciate your replies in advance!

Scott



Filled up a 7 yard dumpster!!!






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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 09/06/2017 at 2:51pm
I used vice grips others have used a sawzall.
 
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 Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 09/07/2017 at 11:54am
Appreciate your reply.  Were you able to remove the wood around first?  Looks like it in the picture but wanted to confirm.

Scott
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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 09/07/2017 at 4:18pm
hole saw around all the screws then vice grips....
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 Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 01/28/2018 at 5:57pm
Quick question for the forum on fencing panels:  Ours is in pretty good shape but with older decals in tact.  Would love a poll of new fencing panels vs. sand and paint.  Thanks in advance!  As an update, finally have most of the decking off with plans to grind rusted bolts this week.  I'm jealous of all the rebuild project owners that have garages!!!  

Scott
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barnmb7117 Quote  Post ReplyReply Direct Link To This Post Posted: 01/28/2018 at 6:37pm
I think it comes down to cost. I would love to replace mine with blue but it would run between 3 and 4 hundred to replace it. Plus the cost of new decals.and to paint it less then a hundred plus decals but I have a compressor and paint guns already.
  I did 2 rebuild in my driveway but it was summer.
Mike
1993 Tracker fishing barge 21
2015 Evinrude pontoon series 90 hp
Summer - On the wolf River Weyauwega, WI
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 01/29/2018 at 1:21am
Thanks Mike for your reply.  I'm torn but leaning towards putting the $295 into the new fence panels.  Either way is tedious but I don't have any painting supplies so...  On a positive note I finally removed all of the old wood deck today.  I pray that process is the most difficult of this rebuild as my hands are hurtin!!!! :-)


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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 01/29/2018 at 1:23am
Craig, hope all is well!  I see you have the same black epoxy like material on the stringers.  Out of curiosity how did you remove?  Thanks!

Scott


Edited by Scott573 - 01/29/2018 at 1:49pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 01/29/2018 at 2:39pm
Hey Scott,


I just scraped it off and left whatever was still there. Used new roll of seal so it really didn't matter. I started my rebuild at the lake lot in March of 2013. With a generator for power!
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 Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 01/31/2018 at 10:49pm
Thanks Craig.  Much appreciated!  I just have on one or two stringers and will just plan to try and get it as flat as possible.  Pulled 3 of 5 fence panels last night...  Easy to pull but nervous how the new will go in.  More pics to come.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barnmb7117 Quote  Post ReplyReply Direct Link To This Post Posted: 02/01/2018 at 4:24pm
take your time with the panels extra hands will help.
Mike
1993 Tracker fishing barge 21
2015 Evinrude pontoon series 90 hp
Summer - On the wolf River Weyauwega, WI
Winter- Chicago, IL
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 02/02/2018 at 6:50pm
Thanks Mike, agreed on taking time, pretty nervous for the curved panels...  Hoping to get one cleaned this weekend and give it a try
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 02/03/2018 at 3:32pm
Next question for the group.  Really appreciate all of the help thus far!  Have been using the Mac's aluminum brightener to clean the existing rub rails.  Pretty simple process:  Spray, let foam up, rinse with cold water, then scrub the remaining areas that didn't take on round 1.  Works pretty well as long as there is no build up of grime on the corners and other surfaces.  Moving on to the fencing...  

Question:  Mac's or Sharkhide to clean the fence? 

Appreciate the advice as always!

Scott






Edited by Scott573 - 02/03/2018 at 8:06pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 02/11/2018 at 3:09pm
Made progress last week.  Following Craig's advice I used WD 40 and vice grips to remove 2/3s of the countersunk screws.  For the remaining that were too rusted out I ground them down flat.  The tar was brutal to scrape of but it's close enough!  Finally ready for new decking; now just have to figure out the delivery logistics.







Also was finally able to remove the steering wheel from the existing "column" using the liquid wrench below.  Just let it soak for a few minutes then 2-3 taps of the hammer and that was it!



Received console and gauges this week.  Planning to cut holes and install them and a new head-unit tonight.  Cheers!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 02/12/2018 at 2:24pm
Sweet! do you know anyone that owns a business in parkville that has a dock??? If not let me know. You should be able to use my company's but we're downtown....PM me if you need to.


 
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 Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 02/12/2018 at 5:48pm
Craig,

Really appreciate the reply and the offer!  Our company has one in south KC that I'm going to try and use...  Just will owe another favor to our mail and fleet team!  I actually just got off phone with PS to place the deck kit order to get it here by Friday as this weekend looks like 50's in MO!!!  

Talk soon,

Scott
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Post Options Post Options   Thanks (0) Thanks(0)   Quote chatfield1 Quote  Post ReplyReply Direct Link To This Post Posted: 02/12/2018 at 6:10pm
Hello there! 

Don't know how far you are on the paneling I saw that you were concerned on how the new would go back in. 

I am working on mine now and opted to attach the new paneling on the outside of the rails with rivets. It sounded like a lot of work to me but turns out it was very easy and gave it more of a modern look!

You can order colored rivets heads online for cheap, you just pre drill a hole and rivet it in. Much more simple than trying to send it back through the old lips that held in the previous paneling. 

I also bought some double sided tape to put on the rails prior to installing the paneling, it keeps it in place for you so you can take you time attching it! Very much worth the extra $30

-Cassie
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 02/12/2018 at 6:31pm
Cassie, really appreciate you reaching out.  The paneling is on my list to tackle this week so perfect timing!  Would you mind posting or sending me a few pictures of how it looks?  I'm so new to all of this that any info would really help.  Definitely interested and thanks again!!!  

Thanks again, Scott
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Post Options Post Options   Thanks (0) Thanks(0)   Quote chatfield1 Quote  Post ReplyReply Direct Link To This Post Posted: 02/12/2018 at 7:00pm

No problem! I have never seen anyone mention the tape on here (figured that out on my own) and that I would share it with you. Makes it so much easier. Here is the website where I got my panels and tape..

http://www.pontoonfence.com/parts.html

and the rivets on this site..

http://www.pontoonspecialists.com/hardware-store/rivets/aluminum-colored-rivets-black-50-pack

They matched perfectly. You can get a hand rivet for about 20 bucks, not hard to squeeze its very easy.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 02/12/2018 at 7:41pm
Awesome, panels look great.  I ordered my fencing from the same website.  Did you have to cut to height or did it match perfectly?  That's my only concern as I have to "cut down" each panel to be the correct height.  Also did you cut by scoring and bending or with shears?  
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Post Options Post Options   Thanks (0) Thanks(0)   Quote chatfield1 Quote  Post ReplyReply Direct Link To This Post Posted: 02/12/2018 at 7:56pm
Thank you! I liked the way it turned out for sure.

So the height did not match everywhere we had to make cuts both ways. Your fencing may be different but for mine I had to cut the height for all but 2 pieces. The website said just use a knife to score and bend off. That’s what we did, scoring it sucks you need to go over it about 3 times for it to make a clean snap. Make sure to change your blade for ever new piece, it take a really sharp knife. Once you get in the groove though and understand what you are doing it gets easier.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 02/12/2018 at 8:30pm
Excellent, that's the exact situation we're going to be in with regards to making two cuts per every section...  Just ordered the rivets!  Let me know if you can think of any other helpful hints in the process (like did you start with one rivet in the upper corner, what spacing did you use, what kind of two-sided tape did you get, etc.).  Thanks again for the advice!  Scott
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Post Options Post Options   Thanks (0) Thanks(0)   Quote chatfield1 Quote  Post ReplyReply Direct Link To This Post Posted: 02/12/2018 at 9:25pm
The tape I used is on the website you got your panels from. 

As far as the rivets I didn't start at any certain spot (the tape holds it mostly in place) I just about every 3-4 inchs a rivet. Except for the corners I needed extra on those you'll see when you do it but the corners was more so every 2 inches.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 02/13/2018 at 2:16am
Started work on the console tonight.  First we taped the templates to the base, then drew the outline for the cuts but left a generous amount of room to "fine tune."  Then drilled several holes to allow for a starting point and finished off the cuts with a saw zaw.  Cut back all of the shavings afterward with a sharp razor blade.  Pretty easy but just have to take things slowly to not over cut.  The accessory panel is especially tedious as there is not much room on either side for a mistake.


















Edited by Scott573 - 02/13/2018 at 2:18am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote PontoonMike Quote  Post ReplyReply Direct Link To This Post Posted: 02/15/2018 at 2:35pm
Looks awesome Scott! Great job on the gauges installation. 
Mike K
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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 02/15/2018 at 3:45pm
Nice! at least you have the new console! I did all my work through an 18 x 12 door!






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 Scott573 Quote  Post ReplyReply Direct Link To This Post Posted: 02/15/2018 at 4:43pm
Thanks Mike and Craig!  Much appreciated.  (Craig, definitely easier to work on when you can separate the upper and lower halves).  Was able to get head unit mounted last night using same method but waiting to finish until we receive a different water-resistant cover later this week.  

Was able to clean some more fencing last night as it was 60 Deg!!!  We used the Napa Aluminum Brightener again which does a great job but I'm still looking for a suggestion of one last step to get the remaining oxidation off. 

New decking and carpet arrives today so a lot of work coming this weekend to take advantage of the 50 deg temps........

Scott








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