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'95 Sun Tracker Party Cruiser 32 restoration

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AZpartycruiser View Drop Down
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    Posted: 12/01/2016 at 7:13pm
Hello from southern Arizona!
Hoping I can leverage some tribal knowledge here as I dive deeper into a rebuild on the '95 PC 32' that I bought recently. Deck is almost clear, with only the genny and tank to be removed. Next up is re-decking the front. Not planning to re-deck under the cabin. And then replacing the roof panels and carpet.
Have read in a previous thread about cabin wall replacement and wonder if y'all can advise at what point the PC walls ceased to structural elements in the design. With a '95, I am assuming my walls are structural, which worries me. They show signs of water damage. So I am planning to replace them but have not decided yet what material to use. Any updated advice on the best material to create the new walls with?
 
This what I started with. Really like the style, and I'm excited to get her updated. :-)
 
Thanks!
Trey
1995 Sun Tracker Party Cruiser 32
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Post Options Post Options   Thanks (1) Thanks(1)   Quote Barnmb7117 Quote  Post ReplyReply Direct Link To This Post Posted: 12/02/2016 at 2:15pm
Can't wait to see this rebuild. post a lot of pictures.
Mike
1993 Tracker fishing barge 21
2015 Evinrude pontoon series 90 hp
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Post Options Post Options   Thanks (1) Thanks(1)   Quote SunBlocker Quote  Post ReplyReply Direct Link To This Post Posted: 12/02/2016 at 4:29pm
Your walls are structural.

IIRC, your year (95) is the last year with the helm on the outside of the cabin.  That means you have the same basic construction as mine (92).

If your walls aren't failing right now, they ultimately will (especially if you have already noticed some water damage).

Take a look at your fencing where the big SunTracker logo is.  Does the sheet metal "bow out" a little bit, or is it perfectly flat?

Wish I had better news.
1992 SunTracker Party Cruiser 41ft
18' Cobalt, 13' ElDebo E-Pontoon
-- Okauchee Lake, WI --
The `Blocker Build
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Post Options Post Options   Thanks (0) Thanks(0)   Quote AZpartycruiser Quote  Post ReplyReply Direct Link To This Post Posted: 12/05/2016 at 5:35pm
Sunblocker, yes the fence aluminum is bowing out. And I knew going into this that I was in for a restoration. In the words of Luke Skywalker, I am not afraid ("You WILL be." -- Master Yoda) I am only going to do this one time, so I want to do it right.  And I specifically wanted the helm outside the cabin so I am glad I found this one. :-)
 
When I am done taking out the galley cabinets and have removed the interior carpet, I want to get on to replacing the outer deck floor. Then on to the cabin walls and roof panels. What is your advice on which to do first? I guess I am thinking that it would be prudent to do the roof first, as I am working on it outdoors, and if it rains while I am doing the walls, I want a good roof in place first. Thoughts?
 
And when replacing the walls, I have thought about adding aluminum posts to the corners for more roof support. Is this viable? 
 
Thanks so much for your help!  And, here are some update images:
 


Edited by AZpartycruiser - 12/05/2016 at 5:37pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SunBlocker Quote  Post ReplyReply Direct Link To This Post Posted: 12/05/2016 at 9:26pm
Replacing the roof first would probably be a wise choice.

My `92 (which is the same basic construction as yours) didn't really require any additional support in the corners, those extrusions were fine.  The mid-span extrusions were a different story since they didn't actually go all the way to the floor and didn't add much to the structure.  I made my own heavy-duty "H-channels" to replace those and mine run all the way from the floor to the bottom of the roof extrusions.  Once that was done I didn't need the actual wall panels to be structural anymore.
1992 SunTracker Party Cruiser 41ft
18' Cobalt, 13' ElDebo E-Pontoon
-- Okauchee Lake, WI --
The `Blocker Build
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Post Options Post Options   Thanks (0) Thanks(0)   Quote AZpartycruiser Quote  Post ReplyReply Direct Link To This Post Posted: 12/06/2016 at 8:15pm
Thanks for the advice! And, I read about how you made the H channels for your side beams using the 8' rulers - love it! And that's good news on the original corner extrusions being enough support.  Thumbs Up
 
Still uncertain about the material to use for the walls. If you were tackling this project now, what would you use -- something in a corrugated/honeycomb plastic/PVC engineered as a single sheet?
 
Taking out the galley cabinets and the cabin carpet today!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SunBlocker Quote  Post ReplyReply Direct Link To This Post Posted: 12/06/2016 at 11:41pm
I think if I had to do it over again I'd probably still go with the material that I used.  That's not me just being stubborn, it has held up well, was easy to install, is light, and was reasonably inexpensive.

BUT.... if I was going to change materials I'd probably look long and hard at a laminate that had an aluminum outer skin.  I always worry about the relative "softness" of my outer skin.... although "dents" can be fixed with a heat gun.

One of the biggest problems is finding an alternate laminate that will fit in the 1" stock channels.  But once you go custom, almost anything is possible.
1992 SunTracker Party Cruiser 41ft
18' Cobalt, 13' ElDebo E-Pontoon
-- Okauchee Lake, WI --
The `Blocker Build
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Post Options Post Options   Thanks (0) Thanks(0)   Quote AZpartycruiser Quote  Post ReplyReply Direct Link To This Post Posted: 12/07/2016 at 6:07pm
Blocker, I have been going back through your rebuild thread and I must be blind. I cannot find where you described in detail what you made your walls out of. Would you mind re-posting here? I've checked out PolyMax board and am really perplexed on which way to go. Any help would be most appreciated.
 
And, what did you use for the "headliner" on underside of the roof panels?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SunBlocker Quote  Post ReplyReply Direct Link To This Post Posted: 12/07/2016 at 7:19pm
Parkland Plastics made my walls for me.  Custom (but very reasonable).  Satin Plastex on both sides of foam.  Nice walls in my opinion.

My headliner was done in pieces.  Made some thin wooden frames that "pop" into the openings in the existing welded/extruded support frame.  Covered them with some high-end shower curtain material and that was it!  Turned out really nice and they're easy to change out.
1992 SunTracker Party Cruiser 41ft
18' Cobalt, 13' ElDebo E-Pontoon
-- Okauchee Lake, WI --
The `Blocker Build
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Post Options Post Options   Thanks (0) Thanks(0)   Quote AZpartycruiser Quote  Post ReplyReply Direct Link To This Post Posted: 12/07/2016 at 8:15pm
Great idea on the ceiling panels!  On my roof, what's your advice on attaching the plywood and waterproofing before I cover the top deck with marine carpet? Is there an adhesive I should use along with screws into the rook extrusions? Some sort of rubber membrane under the carpet to protect the wood?
 
And did Parkland make the 1" panels for you with plas-text cladding? Or did you DIY and glue the thin plas-tex panels to a sheet of insulation to get to 1" thickness?
 
I can get the thinner plas-text sheets at Lowe's but would rather have a professional create cladded panels if possible.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SunBlocker Quote  Post ReplyReply Direct Link To This Post Posted: 12/07/2016 at 9:15pm
Frankly, I'd do the top deck with Lock-Dry or AridDeck if you could (which is what I am using on mine).... but I reckon wood is OK.

The factory covered the UNDERSIDE of the top deck with carpet before installation, so there is carpeting between the wood and the aluminum structure (at least that's how they did it on the `92).  If you're not going to go that route, I would suggest some kind of breathable covering.  Bottom side unsealed, top side sealed.  And liberally slather the screws with silicone before installation.
 
And yes, you want a membrane under the carpet on the top.  The "proper" thing to use is an RV EPDM roof membrane.  I don't know about gluing carpet to EPDM... and that's not what I did.  My upper deck carpet is "snap in" using marine snaps.  That works out really nicely, both for replacement and cleaning.

Parkland made the panels for me (completely), I didn't do any vacuum bagging or laminating myself.
1992 SunTracker Party Cruiser 41ft
18' Cobalt, 13' ElDebo E-Pontoon
-- Okauchee Lake, WI --
The `Blocker Build
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Post Options Post Options   Thanks (0) Thanks(0)   Quote AZpartycruiser Quote  Post ReplyReply Direct Link To This Post Posted: 12/08/2016 at 12:15am
Blocker, thanks for the advice for materials on the roof. Would love to see an image of how your roof looks with the snap-in carpet. Many of the images are not showing for me in your rebuild thread. :-(  Here's a peek at what I found after removing the top rail and roof bezel today. Just carpet and wood. Pretty ugly! (and a recipe for leaks)
 
 
And, I also got one of the large fences off today so you can get a great look at just how crummy of an idea it was for Tracker to use the Masonite cladding. UGH!
 
 
Blocker, would you have a contact person/number/email with Parkland you could refer me to for fabrication of wall panels?  Thanks!


Edited by AZpartycruiser - 12/08/2016 at 12:16am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barnmb7117 Quote  Post ReplyReply Direct Link To This Post Posted: 12/08/2016 at 1:24pm
Could you put up one picture at a time then hit the space bar after each picture. It makes it easier to see.

Mike
1993 Tracker fishing barge 21
2015 Evinrude pontoon series 90 hp
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SunBlocker Quote  Post ReplyReply Direct Link To This Post Posted: 12/08/2016 at 2:54pm
My contact back in 2008 at Parkland was a Mr. Charles Yoder.  Sandy Zann was in charge of customer service.  I have no idea if those people are still with the company.
1992 SunTracker Party Cruiser 41ft
18' Cobalt, 13' ElDebo E-Pontoon
-- Okauchee Lake, WI --
The `Blocker Build
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SunBlocker Quote  Post ReplyReply Direct Link To This Post Posted: 12/08/2016 at 2:59pm
You can see the ceiling panels in this older picture of the interior.  Not sure if I have a better shot of them.




I'll look to see if I have a shot of the snap-in carpet on the top.


Edited by SunBlocker - 12/08/2016 at 3:01pm
1992 SunTracker Party Cruiser 41ft
18' Cobalt, 13' ElDebo E-Pontoon
-- Okauchee Lake, WI --
The `Blocker Build
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SunBlocker Quote  Post ReplyReply Direct Link To This Post Posted: 12/08/2016 at 3:03pm
Here you can see the snap-in carpet on top of the EPDM membrane.

1992 SunTracker Party Cruiser 41ft
18' Cobalt, 13' ElDebo E-Pontoon
-- Okauchee Lake, WI --
The `Blocker Build
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Post Options Post Options   Thanks (0) Thanks(0)   Quote AZpartycruiser Quote  Post ReplyReply Direct Link To This Post Posted: 12/09/2016 at 4:52pm
Blocker, I just spoke with Charles Yoder and I think your project has faded from his memory. LOL! He did not recall them doing any panels like what you described and told me they have nothing that would be suitable of external UV exposure. But he is going to look into it further and see what they might be able to suggest. The quest goes on! 
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SunBlocker Quote  Post ReplyReply Direct Link To This Post Posted: 12/09/2016 at 10:13pm
Ouch!  That hurts my feelings.

I had quite a few EMAIL conversations with Charles about the panels (which were originally designed and fabricated for a different application).  He wasn't concerned abut UV exposure.. and since I had The `Blocker wrapped.... I don't know if there would have been a problem or not.  Thermal expansion is a bit of the problem with the Plastex, but since Parkland did the laminating.... there are no issues.
1992 SunTracker Party Cruiser 41ft
18' Cobalt, 13' ElDebo E-Pontoon
-- Okauchee Lake, WI --
The `Blocker Build
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Post Options Post Options   Thanks (0) Thanks(0)   Quote AZpartycruiser Quote  Post ReplyReply Direct Link To This Post Posted: 12/10/2016 at 6:03pm
Do you have the specs they used on your panels? I think it might help me help him remember.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote AZpartycruiser Quote  Post ReplyReply Direct Link To This Post Posted: 12/14/2016 at 6:54pm
While I am working to source the cabin panels, it is time to get started on the deck. Has anyone here used composite deck boards for a pontoon floor?  I like the idea of having a durable material for the floor that I don't have to put carpet on if I so choose. I've had decks on my homes in the past made of the composite material and like the way they stand up to moisture/rain. What are the reasons I would not want to go this route?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SunBlocker Quote  Post ReplyReply Direct Link To This Post Posted: 12/14/2016 at 9:14pm
Depends on what composite material you are talking about.  The typical composite decking is REALLY heavy (compared to plywood or aluminum).  Honestly, this is NOT a good choice.

Now a composite like Coosa board might work nicely, but that stuff can get kinda pricey.

What specifically were you thinking about?
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18' Cobalt, 13' ElDebo E-Pontoon
-- Okauchee Lake, WI --
The `Blocker Build
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SunBlocker Quote  Post ReplyReply Direct Link To This Post Posted: 12/14/2016 at 9:18pm
Originally posted by AZpartycruiser AZpartycruiser wrote:

Do you have the specs they used on your panels? I think it might help me help him remember.

The specs are pretty simple.  Satin matte silk Plastex on both sides of bead foam with a finished thickness of 1".

It ended up being bead foam because that was the only foam that they could get in a custom thickness that would yield the final panel thickness of 1" that I wanted.

I received my panels in January of 2009.
1992 SunTracker Party Cruiser 41ft
18' Cobalt, 13' ElDebo E-Pontoon
-- Okauchee Lake, WI --
The `Blocker Build
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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 2:20am
If you're looking for flooring for a pontoon that doesn't need to be covered, look at Skidguard from olympic:

http://www.olypanel.com/industrials.php

My neighbor redid his pontoon with that stuff.  The yellow looked pretty nice, and as advertised, it's skid resistant.  I think the primary use is for docks, so it should work in a marine environment...

I looked at it for my rebuild.  Only disadvantage is price.  My local source was $125/panel.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote AZpartycruiser Quote  Post ReplyReply Direct Link To This Post Posted: 12/15/2016 at 8:13pm
Thanks for the suggestion, Fast! I will check it out. On my PC I see that the existing deck panels are 5/8" thick, which I am having trouble finding marine plywood in 8.5' width. 3/4" thickness is easy to get but it is too thick for the loooong, single piece side trims to fit back on properly.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote CapnCrunch Quote  Post ReplyReply Direct Link To This Post Posted: 12/16/2016 at 7:52am
How about routing an eighth inch off the edges of the 3/4 plywood sheets so they fit within the trim pieces and then tapering the routed edge a few inches with a sander (I assume you will be carpeting the deck).  Question
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Capn, I think that may be what I end up deciding to do. We are thinking alike. :-)
And, I am thinking it will be much better to use 3/4" sheets as opposed to 5/8".  I am undecided on carpet vs. vinyl for the floor covering. I know I want carpet but have seen some nice applications of snap-in carpet over marine vinyl.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote AZpartycruiser Quote  Post ReplyReply Direct Link To This Post Posted: 12/21/2016 at 4:54pm
UPDATE
I have my plywood in my garage now! Eager to get started on the roof but rain is in the forecast (in Phoenix?!?!?!) So it may be next week before I can get started. Thinking I will use this RV roof covering and then install snap-in carpeting: 
http://www.ebay.com/itm/291516983235?_trksid=p2055119.m1438.l2649&ssPageName=STRK%3AMEBIDX%3AIT
 
I am undecided on what to use as a headliner on the underside of the roof panels. Still searching for the right material.
 
WALLS
And on the walls after much searching, I am leaning toward this option, which is all one piece, super lightweight, WATERPROOF, and intended to stand up against UV exposure:
 
 
Should also be easy to cut for the window openings. I will install additional four additional 1" square extrusions to support the roof and take the load off the walls.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Fast351 Quote  Post ReplyReply Direct Link To This Post Posted: 12/21/2016 at 5:56pm
RE: Snap in carpet. 

GREAT idea!  I have it on one of my ski boats and absolutely love it.  However, you will eventually pull out a couple of snaps.  When you do, resist temptation to buy a $25 snap tool.  They are all junk (I have two to prove it). 

I bought the last snap tool I will ever need:

http://www.hooverproducts.com/interest.htm

It's the same tool the carpet company sent me when I initially replaced the snap in carpet. 

Good luck with the rebuild!

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Post Options Post Options   Thanks (0) Thanks(0)   Quote Morganh Quote  Post ReplyReply Direct Link To This Post Posted: 03/24/2017 at 12:42pm
AZ,
I dont know how far you are in yet, and havent been on for a while, but I see where you have read my rebuild on the same boat.  Let me go over a couple of things I did.
Roof - I did not tear my down and rebuild when I did my walls, although I wish I had.  I sealed them with a roofing fiber type paint/tar and did a couple of coats.  Then as it has dried and cracked a little over time, I go over all defect with 100% silicone caulk, and it stays dry below.  I then put the "grass tiles" over it, so I have a grass roof that water can run under and get to the drains.  Everytime someone gets on my roof, they are stunned at the soft grass, and it has been the sunbathing layout preference.

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'86 Ski Supreme
'34 Ford Ratrod
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