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91 20' Weeres Sportsman Deluxe restore this winter

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Fast351 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Fast351 Quote  Post ReplyReply Direct Link To This Post Topic: 91 20' Weeres Sportsman Deluxe restore this winter
    Posted: 09/13/2016 at 8:15pm
I bought a "new to us" pontoon last year for a smokin' deal.  I basically paid for the motor, and got the pontoon for free Smile

Anyway, this winter I will be tackling recarpeting the floor and probably replacing the plywood.  We've used it all year and while it doesn't appear to have any soft spots in it, why go through the effort of completely stripping the pontoon and cheap out and save maybe $300 and have to go through it again at some later date.  But I digress....

The boat was "revinyl"ed a couple years ago and the vinyl is in great shape.  The motor, as I mentioned, is nearly new.  It's a 25HP Yamaha 4 stroke.  The rest of the pontoon is "vintage" 1991 Weeres though Smile

As you can see from the pics below, the carpet is a lovely pink.  I assume it was red at some point judging by the color inside the seats.  I did pressure wash it before this season after these pictures were taken.  A disgusting job, the moss and other crud growing on there was, well, disgusting. 

So, a couple questions:

1) I want to redo the side panels.  Not sure what the names are but the ones with vinyl on them and the mailbox letter registration stickers.  It's a marble textured aluminum.  I assume the best thing to do is drill all the rivets and then strip the vinyl, lettering, and repaint.  What's the best process for this?

2) The railing elevation seems like a really neat idea.  Has anyone ever tried to do that with the seats themselves?  A couple of blocks under the seats to raise the seats the same amount would keep the insides of the seats dryer and make it easier to rinse the deck off.  I ask because there are screws from the railing into the seat back, and if I raised the railings, those holes wouldn't line up. 

Some pictures.  Here you can see the faded stickering on the sides:

Pre teardown

And the wonderful red carpet:

Old Interior

All the black crud is gone from it, but the carpet is still very faded.

Thanks in advance for the advise!


Edited by Fast351 - 12/20/2016 at 2:38pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barnmb7117 Quote  Post ReplyReply Direct Link To This Post Posted: 09/13/2016 at 11:16pm
Good luck with the rebuild keep us posted and the pictures coming.
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 Fast351 Quote  Post ReplyReply Direct Link To This Post Posted: 11/20/2016 at 8:54pm
And so it begins...

Going to replace the console.  I think I'll keep the seats, but the Black Friday sale is really making it tempting to just wholesale replace everything...

Partial teardown

Stripped deck




Edited by Fast351 - 12/20/2016 at 2:40pm
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Post Options Post Options   Thanks (1) Thanks(1)   Quote Barnmb7117 Quote  Post ReplyReply Direct Link To This Post Posted: 11/22/2016 at 3:09am
Go to their facebook page and enter to win a pontoon seat package. They have a new contest every week and the drawing is on  Fridays.  Make sure to do all three step to enter and good luck.  https://www.facebook.com/PontoonStuff/?fref=ts
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 Fast351 Quote  Post ReplyReply Direct Link To This Post Posted: 11/25/2016 at 11:15pm
Stripped railings

Stripped frame

Old floor


Edited by Fast351 - 12/20/2016 at 2:44pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Fast351 Quote  Post ReplyReply Direct Link To This Post Posted: 11/25/2016 at 11:16pm
Stuff's getting real now.  Got the railings stripped of their old aluminum, and the floor is removed from the frame.  Not much left before the new plywood goes on...



Edited by Fast351 - 11/25/2016 at 11:17pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Fast351 Quote  Post ReplyReply Direct Link To This Post Posted: 11/26/2016 at 10:32pm
Consoles

Swapping consoles.  Out with the old, in with the new.  Got the control panel, steering box, and horn moved over.


Edited by Fast351 - 12/20/2016 at 2:46pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barnmb7117 Quote  Post ReplyReply Direct Link To This Post Posted: 11/27/2016 at 12:21pm
Clap  Looking good. Like your building your are working in.
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 Fast351 Quote  Post ReplyReply Direct Link To This Post Posted: 11/28/2016 at 2:19pm
Yeah, you gotta have space Smile  Good lighting helps too.  Unfortunately it's not heated to I'm going to have to move it to my little 20x24 car garage to do the carpet. 

Today's small project, replacement table leg mount from Pontoonstuff.  Had to drill and tap for new holes in old polycrylic plastic (nice and brittle).  Fortunately we work with stuff at work all the time that needs to be tapped, so I brought it in.  Some 10-24 stainless screws and it's good to go:

Table mount





Edited by Fast351 - 12/20/2016 at 2:46pm
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Oh, and this didn't look like it was coming off in one piece:

Old capacity plate

So I ordered a new one from https://www.garzonstudio.com/boat/capacity-decal.html

$20.  It isn't required by federal law (only the manufacturer needs to put it on, but there is no federal law to keep it intact, it's for driver information only).  However some states require it.  I don't think Minnesota does, but the DNR sometimes uses it to make sure you're not over the number of people.


Edited by Fast351 - 12/20/2016 at 2:47pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barnmb7117 Quote  Post ReplyReply Direct Link To This Post Posted: 11/28/2016 at 3:29pm
Glad to see you are using Stainless steel screws. Don't forget to put fence raisers under the railing.

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 Fast351 Quote  Post ReplyReply Direct Link To This Post Posted: 11/29/2016 at 8:12pm
Hey, look what arrived today!

Pallet of flooring

So you want to have this shipped right to your home?  Pontoonstuff's website does say commercial address only, but they will ship to your residence, assuming you have one of these Smile  The Fedex guy even called me an hour before arriving so I could drive home from work to go receive it. 


Skid steer



Edited by Fast351 - 12/20/2016 at 2:54pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Fast351 Quote  Post ReplyReply Direct Link To This Post Posted: 12/02/2016 at 1:38am
A little progress to report for tonight.  Got a pile of packages over the last couple of days. 

The new capacity plate came in.  It looks fantastic (the weird shimmer is because I snapped the pic with it still in the protective baggy):

New capacity plate

I bought a 1/4" thick 11"x11" aluminum plate to replace the plywood with lousy vinyl and trim falling off that used to hold up the throttle controls:

New throttle plate

The new aluminum for the fencing also came in tonight.  This is corrugated indigo blue fencing.  It should really update the look, as this is kind of what all the new pontoons are going to.  Also got some edge trim, and the vinyl kit from PontoonStuff with the graphics.   My brother has a pretty good metal working shop, so we're planning on tackling that on Saturday:

Fence Aluminum Indigo Blue

And finally, I got some new "tube threads".  There were metal discs just shoved into the brace railings on the front of the pontoon.  It didn't seem like a real secure method of attaching those railings to the deck, and since I occasionally tie the anchor line to that, I figured it should probably be changed.  These are pieces that I think come out of a desk with feet.  Not sure, but they fit the 1" square tube perfectly:

New tube threads

Tube inserts installed

That's it for now.  Should have a few more pictures this weekend.  If I feel really energetic, the decking might get secured Sunday.




Edited by Fast351 - 12/20/2016 at 3:00pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Fast351 Quote  Post ReplyReply Direct Link To This Post Posted: 12/04/2016 at 12:24am
So the job of reskinning the fence started today.  Didn't QUITE get everything done.  Spent about 8 hours at it today with my brother, who has a shop he uses to build circle track race cars.  That means he has all the tools to work with sheetmetal, like a shear, corner notcher, brake, and air riveter.  Here we're cutting the sheetmetal to size:

Size sheetmetal

Then we fastened the corners using Cleco fasteners to hold them temporarily in place.  First we drilled the corners, where we had to hit the existing holes for the rivets.  Thankfully the manufacturer used 1/8" rivets, where we're using 3/16, which means the holes didn't have to perfectly align to the corners.  Once the corners were secured, we drilled the rest of the holes for the sheetmetal.

Drill fence
This guys is a big help!

Big helper

Once the holes were all drilled, we laid just the sheetmetal on the table, removed the protective plastic, and applied the vinyl graphics from PontoonStuff.  Very nice grade 3M material.  Once that was on, the sheetmetal was riveted to the railings, and here is the final result:

Starboard fence done

Total time today 8 hours and we have a couple more hours tomorrow to finish the other side.  It's a lot of work, but it sure looks nice.  Well worth the $350 for the fence aluminum and graphics.  It should really dress things up.



Edited by Fast351 - 12/20/2016 at 3:01pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barnmb7117 Quote  Post ReplyReply Direct Link To This Post Posted: 12/04/2016 at 4:10am
ClapClapClap looks really nice. That is the color I want. When are you coming to Wisconsin to do mine?
Mike
1993 Tracker fishing barge 21
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Summer - On the wolf River Weyauwega, WI
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barnmb7117 Quote  Post ReplyReply Direct Link To This Post Posted: 12/04/2016 at 11:03am
Did you think of painting the rails frame? I see a lot of manufactures doing that now. I thought if i ever reskin my pontoon I would paint the rails black or white.
Mike
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Winter- Chicago, IL
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In my case, the railings were in decent shape, and they're clear anodized.  I did consider powdercoating them, but would have had to strip all the clearcoat first, at which point I lost interest.

I did do a fair amount of research on this subject.  The consensus seems to be that powdercoat is a really nice finish initially but will chip eventually and is not able to be field repaired.  Paint on the other hand can be retouched, but it's all in the prep work.  Use a good scuff base on the aluminum, use several coats of etching primer, and then a coat of good automotive paint. 

At the end of the day, it's a lot of work, but if you're patient you can make it look awesome. 

You're on your own as far as your pontoon Tongue  One is enough for me...
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Day 2.  Here is the process for applying the vinyl.  Get a large table.  We used a couple 6' tables pushed together.  You don't need to be able to put the entire side on the tables, but it sure helps.  Fortunately with the "Sportsman" package, the playpen area is only 12'.  If you have a bigger area, maybe see if you can figure out a way to push 3 tables together.  Anyway, we laid out the vinyl pattern.  Then take a panel in the middle (preferably a small one, like the door we used) and tape the vinyl stripes on the adjacent panels down.  Then cut the vinyl between the panels, remove the protective film, and apply to the middle panel.  Once that's done, use the middle panel as a guide for the adjacent panels, and so on.  Here you can see the door is down and the backer is peeled, and we're just starting the main body panel.



Lay out graphics

Do not even attempt to do this without an air riveter.  You do not have enough hand strength to do all the rivets for an entire pontoon boats' worth of fencing by hand.  Even with the air riveter it was hard work.

Install rivets

I used black rivets on the blue metal.  I think black rivets would probably look pretty good on any metal aside white and off white (like burgundy).  You can buy them at a race car shop, these were $13.95 for a box of 250.  Get a good brand, like the actual "POP" brand.

Rivets corner closeup

And here is the port side finished.  This will really class up the pontoon!

Port fence done

Speaking of rivets, this is how many I had left, zero.  I had EXACTLY the right number of rivets.  (My brother did have the same ones on hand, about a third of a box).  If you are buying rivets and your fence is longer than mine (which is probably is), buy two boxes. 

Empty rivets

I thought I might try to get the floor attached today, but I'm tired.  More later...


Edited by Fast351 - 12/20/2016 at 3:06pm
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Moved the pontoon into the little garage with heat.  A bit of a squeeze, but I should be able to get it up to the required 60 degrees to get the carpet put down.   (It's 13 outside right now).  Screw on the decking tonight/tomorrow, get the carpet down, and by the end of the weekend, should have a carpeted deck!

Frame in garage


Edited by Fast351 - 12/20/2016 at 3:07pm
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Don't forget to check the frame for square. The fencing came out real nice.
Mike
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Summer - On the wolf River Weyauwega, WI
Winter- Chicago, IL
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Got the deck down tonight and the carpet rolled out. 

Screw deck

Half carpet

Half carpet

Rolled out carpet

Tomorrow glue and roller...


Edited by Fast351 - 12/20/2016 at 3:10pm
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Carpet is glued down.  Went really quick actually.  I bet from the time I started pouring glue to the time I finished vacuuming was under an hour. 

Pics:

Pour glue

Roll glue

Roll carpet

Pour glue






Edited by Fast351 - 12/20/2016 at 3:15pm
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Roll glue

Roll carpet

Finished product:

Trim carpet




Edited by Fast351 - 12/20/2016 at 3:16pm
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Edging polished and back on, new cleats up front, table leg in.  Not much else I can do this weekend, since I need stuff from Fastenal for the fencing...

Aluminum edging


Edited by Fast351 - 12/20/2016 at 3:17pm
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ClapClapClap looking good.
Mike
1993 Tracker fishing barge 21
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Summer - On the wolf River Weyauwega, WI
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Post Options Post Options   Thanks (0) Thanks(0)   Quote CapnCrunch Quote  Post ReplyReply Direct Link To This Post Posted: 12/11/2016 at 7:47pm
Thank you for the thorough photo documentation.  Your project looks like a professional restoration and I expect the toon will look like brand new when you're through.  Well done.  Thumbs Up
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Tonight's progress.  Forward grab rails, console (with routing steering cable), and captains chair.

All new stainless fasteners.  Hopefully they will come off if they ever need to.

Grab rails (and new cleats as opposed to the old hook):

Grab Rail

New PontoonStuff console and captains chair.  The bottom of the chair stem used to just sit on the wood floor.  As you swiveled, it chewed through the wood.  I screwed a piece of 1/4" Delrin under it to hold the shaft up.  That should prevent floor damage. 

The console was secured using 4x  5/16-18 stainless bolts with locknuts underneath. 

Helm


Edited by Fast351 - 12/20/2016 at 2:37pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barnmb7117 Quote  Post ReplyReply Direct Link To This Post Posted: 12/13/2016 at 1:22pm
Looking real good. Are you going to polish the tubes? Thanks for posting pictures.

Mike
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Summer - On the wolf River Weyauwega, WI
Winter- Chicago, IL
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Fast351 Quote  Post ReplyReply Direct Link To This Post Posted: 12/13/2016 at 5:05pm
Probably not.  I considered it, but I'm not all that excited about adding yet another item to my fleet maintenance list.  I might hit them with a cleaner this spring before I dunk it just to get some of the really caked on crud off, but that's about it. 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Fast351 Quote  Post ReplyReply Direct Link To This Post Posted: 12/15/2016 at 2:03am
Tonight's progress, rear fencing and the plate over rear of the toon that holds up the gas tank:

Rear fence

Tank plate

Rear fence


Edited by Fast351 - 12/20/2016 at 3:19pm
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