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1987 Harris Flotebote 240 Classic Restoration

Printed From: Pontoon Forum
Category: Show Off Your Pontoon Boat
Forum Name: Pontoon Boat Rebuild Projects
Forum Description: Members/Customers who are rebuilding their Pontoon Boats
URL: http://www.pontoonboatforum.com/forum_posts.asp?TID=8799
Printed Date: 11/18/2018 at 11:38pm
Software Version: Web Wiz Forums 11.01 - http://www.webwizforums.com


Topic: 1987 Harris Flotebote 240 Classic Restoration
Posted By: gerard143
Subject: 1987 Harris Flotebote 240 Classic Restoration
Date Posted: 07/20/2017 at 9:01pm
Well I picked up my first pontoon boat.   Prior to this a few years back I owned a 1994 regal valanti 222se open bow with a 350 that I did some restore work on. 

I have been wanting a boat again and starting looking at pontoons over the last couple months.   I can across this baby on a drive to sylvan beach in ny with the gf.   She suggested we stop at the marina on the way back and check out what they had.  At first glance I scoffed it off but over the next two weeks I kept coming back to pictures I had taken of this boat and made a second trip out to look at it.  Then I wound up closing the deal for $4,000 with a 2011 Venture Trailer and a 90 horse johnson on the back.   

Overall I decided I liked the design of the boat itself plus the newer trailer and 90 horse motor rounded it out well.   It seemed like a good starting point for a nice restoration project.   Especially for 4,000.  It even came with a minn kota edge 70 trolling motor ($600) and an older fish finder.  An electric winch on the trailer, a fairly new bimini top and a mooring cover.  Looks like the logs are 23-24" in diameter.  Was hard to get an exact measurement. 

I have some big plans for the boat.   I think this is going to be an exciting build and I am pretty meticulous in my work so you guys might enjoy this thread yourselves.     

The boat is a 1987 and the motor it turns out is actually a 1993. 
 
Here are some photos.

 

 


 
 

 

 
 
 
 
 
 
 
 
 
 

 



Replies:
Posted By: JLester273
Date Posted: 07/20/2017 at 10:29pm
I'm in the same boat. Pun intended. 

I have a 1988 Harris Flote Bote 240 Sunliner

I jumped on mine when I saw it. Very nice for the money I paid. But I am redoing it this winter. I actually just got some stuff today for the trailer from the PS guys. 

So much cool stuff you can do with a rebuild. I look forward to swapping ideas since we are both building similar boats. 


-------------
1988 Harris 24 ft
Soon to be a Pontoon Stuff Rebuild


Posted By: gerard143
Date Posted: 07/20/2017 at 11:41pm
I have a whole list of stuff I plan to order in a couple of days.   But the core of it.... the carpeting/seats/console/painting will happen in the off season.    I am excited but it is going to be a lot of work for sure.     I'd really like to get some decent speed out of it... so I might even consider adding a third pontoon plus lift strakes if the speed isn't to my liking.  I am considering going bigger/newer on the motor.  I'll guess i'll have to see what she can do with this 90 horse and go from there but I'd really like to be able to hit 40.
 
 


Posted By: p3cflyr
Date Posted: 07/21/2017 at 12:01am
Do i understand you would like to do 40mph with your pontoon boat???  You will need a bigger motor (250hp may be enough).  Adding a center tube will add drag and probably reduce your top end speed (ask me how i know).  You would also have to replace the current tubes with bigger ones with strakes.  Pontoon boats do not plane, they plow through the water.  To me 40mph is unrealistic unless ya got lots of $$.  I hope others will join in and I'd be happy for them to prove me wrong!!


-------------
Mike

"Atta Boy" Award June 2011
1987 Lowes Fish and Fun 20ft
1999 Merc 50hp 4 strk big foot
Kirksville, Mo
P3C Orion Pilot
ASW Warfare Specialist


Posted By: gerard143
Date Posted: 07/21/2017 at 4:20am
From everything I've read generally the only pontoons that break 40 are tritoons and that the third toon generally makes it act much more like a hull that planes.   But yes I realize decent horsepower is also required.   


Posted By: JLester273
Date Posted: 07/21/2017 at 1:10pm
You will probably get 21-22 mph with your current setup...I would guess.  I have a 75 and get 19. 

I'll be tearing mine down to the cross members and will likely reinforce that for good measure while I am there. But I'm reading bigger toons than I have make a big difference. So at some point down the line I may opt to change the toons and possibly add a center toon as well if I decided to repower it. 

But for now 19 will do. I hope for a little increase getting rid of the old wood bases. And moving to the roto-molded ones. Hopefully that is less weight. We shall see. 



Are you replacing your deck when you do the carpet? I'm going to go with the new deck and the 80 mil vinyl PS offers. That way I can power wash it out with no worries later. We fish mostly so I have to think of cleanup. I don't want it to smell like the fish cleaning station all the time. 


-------------
1988 Harris 24 ft
Soon to be a Pontoon Stuff Rebuild


Posted By: p3cflyr
Date Posted: 07/21/2017 at 3:40pm
I put a third tube under my 20 footer.  gained support for weight and lost 4 mph.  Raised the boat about 4 inches which is what I wanted.  Was surprised at the speed lost.  anyway good luck and I hope you can get the 40!!


-------------
Mike

"Atta Boy" Award June 2011
1987 Lowes Fish and Fun 20ft
1999 Merc 50hp 4 strk big foot
Kirksville, Mo
P3C Orion Pilot
ASW Warfare Specialist


Posted By: gerard143
Date Posted: 07/21/2017 at 4:25pm
Originally posted by JLester273 JLester273 wrote:



But for now 19 will do. I hope for a little increase getting rid of the old wood bases. And moving to the roto-molded ones. Hopefully that is less weight. We shall see. 


Are you replacing your deck when you do the carpet? I'm going to go with the new deck and the 80 mil vinyl PS offers. That way I can power wash it out with no worries later. We fish mostly so I have to think of cleanup. I don't want it to smell like the fish cleaning station all the time. 


Yes replacing the deck for sure.   I plan to go with woven vinyl instead of carpet and aqua tread imaged wood up front. 



Posted By: gerard143
Date Posted: 07/21/2017 at 4:26pm
Originally posted by p3cflyr p3cflyr wrote:

I put a third tube under my 20 footer.  gained support for weight and lost 4 mph.  Raised the boat about 4 inches which is what I wanted.  Was surprised at the speed lost.  anyway good luck and I hope you can get the 40!!


Ya I am surprised too.  Thats interesting.  I figured they would all see a serious speed improvement with the 3rd toon.   


Posted By: JLester273
Date Posted: 07/21/2017 at 9:51pm
You lost speed because you didn't re-power ...or so I've been told you need to go high HP so get the advantage of the 3rd toon. Not sure what you have power wise but I've been told that is how you gain the advantages pertaining to speed. 


Yeah I have seen some nice setups. I passed LCI when up visiting PS last week. I have some LCI stuff on my Forest River camper. Of course they are right there too. 
My guess is the more custom stuff will be pricey. Not the I would call the PS stuff cheap. Seeing it in person I really like it. But yeah they have some really sweet custom stuff. 




-------------
1988 Harris 24 ft
Soon to be a Pontoon Stuff Rebuild


Posted By: JLester273
Date Posted: 07/21/2017 at 10:04pm
I just tried Lipert's deck configuration software. with the seats they offer on it I can't even get the back configured to fit. They have some odd sizes...at least from what I see. Maybe there custom stuff is different. 

Oh well PS is where I am getting mine. But it was interesting using their's. some things I like other things I didn't.

keep us updated. 


-------------
1988 Harris 24 ft
Soon to be a Pontoon Stuff Rebuild


Posted By: gerard143
Date Posted: 07/21/2017 at 11:26pm
Originally posted by JLester273 JLester273 wrote:


Not sure I would call the PS stuff cheap. Seeing it in person I really like it. But yeah they have some really sweet custom stuff. 

Ya I don't really mean to refer to it is cheap.  They are the nicest overall aftermarket ones i've found imho.  Just looking for something a tad higher end. 


Posted By: JLester273
Date Posted: 07/22/2017 at 3:46am
I didn't take your comments that way. I meant it toward me. PS furniture is going to be cheaper than custom stuff. But by no means seems cheaply made to me. Guess I didn't explain myself good enough. 

Some of the pics they show on the one link are amazing looking. I'm sure they make good stuff. I think all there is a ton of people trying to get into or stay in the market. Which makes it a good thing for us in a that competition makes them push for innovation and stay relatively reasonable prices. 

I still feel building a boat is cheaper than buying one. At least when it comes to some of the 75k plus ones. 


-------------
1988 Harris 24 ft
Soon to be a Pontoon Stuff Rebuild


Posted By: gerard143
Date Posted: 07/24/2017 at 2:43am
ya i was looking at pontoons that are 12 grand and still need seats replaced cuz of cracks or fading.   So i said ya know what... I'm gonna spend that much for what... a pontoon that basically looks the same on the exterior... still needs the seats redone or replaced?   Or i'll save 8 grand and do a full rebuild and have the thing look incredible and exactly to my liking.   I will use it for 4 years and probably be able to sell it for what I have into it.    

Other then my time and labor involved I think its a good route to go. 


Posted By: JLester273
Date Posted: 07/24/2017 at 5:23am
I agree I like customizing it the way I want to anyway. When you buy new your worried about changing anything. 

Can't wait to see what you make of it.


-------------
1988 Harris 24 ft
Soon to be a Pontoon Stuff Rebuild


Posted By: gerard143
Date Posted: 07/24/2017 at 6:09pm
Well my first purchase for it arrived lol.  A porta potti.    https://www.amazon.com/Thetford-92360-Porta-Portable-Toilet/dp/B006WPQNB2/ref=sr_1_fkmr0_2?ie=UTF8&qid=1500915935&sr=8-2-fkmr0&keywords=thetford+curved" rel="nofollow - Thetford 92360 Porta Potti 550E Curve Portable Toilet

It is wicked nice.  I recommend it.   Battery powered flush.  Nice height.  Curved Design.  Toilet Paper holder compartment.   Pretty slick unit.   

Also ordered an outdoor tankless water heater.   I'd like to be able to maybe take a weekend trip on this thing and rinse off if I want.   So i figure i'll rig up a tankless water heater and run the hose up near the bow.   I found wicked pricing on a unit that reviews well.    https://www.eccotemp.com/eccotemp-l5-tankless-water-heater-w-flojet-pump-strainer/" rel="nofollow - Eccotemp L5 Tankless Water Heater w/ Flojet Pump & Strainer   with the discount code welcome20 its $135, awesome.  

Tomorrow I'm ordering a vhf and antenna, 3 way tow harness for tubing/wakeboarding,  https://www.westmarine.com/buy/raymarine--axiom-9-rv-multi-function-display-with-realvision-and-navionics-north-america-charts--18083642" rel="nofollow - AXIOM 9 RV Multi-function Display with RealVision™ and Navionics+ North America Charts  and transducer,  https://www.amazon.com/gp/product/B011QR610I/ref=ox_sc_act_title_4?smid=ATVPDKIKX0DER&psc=1" rel="nofollow - Extreme Max 3005.3430 Under-Mount Pontoon Ladder - 5-Step ,  https://www.westmarine.com/buy/sail-systems--covered-fire-extinguisher-box--6871230" rel="nofollow - Covered Fire Extinguisher Box,  some white diamond metal polish, retractable tie downs for bow and stern to trailer, wakeboard, adjustable fender grips and new fenders, anchor kit, removable ladder, dock lines, some slick pool floats...  https://secure.overtons.com/modperl/product/details.cgi?i=39651" rel="nofollow - Gail Force Connectable Pool Float Navy  with  https://secure.overtons.com/modperl/product/details.cgi?i=40369" rel="nofollow - Gail Force Connectable Cooler Tray Navy  and a couple other odds and ends.  

I have west marine $15 off 200 codes so going to make a couple of separate purchases to maximize that discount.   Also have overtons 20% off code for entire order.  I notice their inventory management sucks. Most of their stuff is on backorder. 

About 1/2 mile from me they sell marine grade AB plywood which is nicer stuff then pontoonstuff or overtons sells for $96 a sheet. 

For flooring (waiting on samples to decide for sure) I plan to do woven vinyl then the fake teak up front on the deck.  http://www.sailrite.com/Fabrics/Marine-Fabric/Marine-Flooring  charcoal or gray from this page I'm thinking.  

Also scored a nice battery charger with $20 off on northern tool  coupon code 254449.   javascript:void%280%29;" rel="nofollow - NPower XRP Series 7-Stage Battery Charger — 12 Volt, Model# 60109
javascript:void%280%29;" rel="nofollow -  
Anyways let the cash burn begin i suppose.  https://secure.overtons.com/modperl/product/details.cgi?i=39651" rel="nofollow -   https://www.amazon.com/gp/product/B011QR610I/ref=ox_sc_act_title_4?smid=ATVPDKIKX0DER&psc=1" rel="nofollow -  



Posted By: gerard143
Date Posted: 07/31/2017 at 4:10am
Well I took her out for her maiden voyage this weekend.    Went up to Alexandria Bay (NY).  


Had it out friday, sat, sun.  Boat ran good but once its warm the idle is just too low and it'll stall a lot when trying to maneuver around docks which isn't a good thing.  I'll have to raise the idle.

I also have a ton of throw on my shifter/hand throttle unit before rpms ramp up.    Like the lever moves 5 inches in forward or reverse before rpms rise.   Is this normal?  

I am getting bad prop walk.  Gotta adjust the trim tab.

JLester you nailed it.  She will do 22 mph steadily.    22 feels faster then I thought.    So i'm revising my desire to be able to do 40.   I think 30mph out of her would be pretty good.  35 would be wicked.   I wonder with lifting strakes, skinning the underside and bumping up to a modern 115 etec motor if that would do it.  I read bumping from a 90 to 115 generally adds 3mph.  I wonder if i could toss a 150 on this.    Not sure why i couldn't.   Never motors have to be lighter then the older ones.    

Another thing is the motor is horrible on gas.   I went thru 15.5 gallons in 30 miles.  At least half of it was at full throttle or close to it.    Is this normal? 







Posted By: JLester273
Date Posted: 08/07/2017 at 4:17am
Good to hear you got it out. 

Mine has a long throw on the throttle before I get into it then seems to not take long to get to WOT. I haven't looked into adjusting mine yet. I hope there is a way to do that. 

Mine does't seem to pull one way or another but my steering is stiff. I plan to replace that this fall. I've heard bigger motors do this more ... hydraulic steering might be something to look at to fix that.


-------------
1988 Harris 24 ft
Soon to be a Pontoon Stuff Rebuild


Posted By: gerard143
Date Posted: 05/13/2018 at 2:28am
Well folks I have began my rebuild!   I lot of things to consider as I rework this boat and try to incorporate everything I would like to have.   I am also trying to plan for the future with it as well. Ladder placement, a changing room, seat layout, wash down pump, stereo configuration, grill location, sink location, storage locations, etc.    So much to consider.  

I wil walk you thru some of the photos below:




Here are my seats and bases from pontoon stuff.   Some of the bases I was unhappy with so they sent more.  This is actually about 4 rows deep in the box truck (I own an old uhaul 14 ft box truck), tons of boxes, probably 45 boxes.  Also in this photo is the new decking from pontoon stuff.    Amazed they ship all this stuff free.  Idk how they do it.  The wood isn't too bad, tongue and groove would be nice though.  



I plan to repaint my motor this color.  Love this johnson platinum color. 




Here is the beginning of the teardown.


Here is all the furniture gone.  Sold the old stuff for $150.  I wish I asked more i had about 75 interested people on craigslist. 


The gf stripped what was left of the old junk carpet off for me while I was at work.  It was nice as it was easy to find the old self tapping screw heads to get the decking off. 



Here she is with the decking off.   Total time invested to get this far in the project was about 4 hours.



Here is a picture of my transom.  I am relocating it back one cross member.  I have to buy a new piece of Z channel as the old setup had a cutout and the motor was recessed in around the fencing.   While I do like this look the issue is when I replace the motor all the new ones are taller and will hit the sundeck.  I went back and forth on this.   I said man... if I make the cutout just to accommodate this motor for a year or two until I replace then I have to patch it and patch in a piece of the woven vinyl flooring.  I really didn't like that idea.  So after the teardown I ultimately decided the easiest method for now is to move the transom back.   This way when I install the new decking I don't have to cut out the large area just to have to patch it all later.  I can lay a full sheet, modify the center portion of the fence at the rear and panel right over it.   This also gives me more room for storage under the sundeck.   A lot more.   The motor will stick out further but oh well I guess.   All the new boats seem to have gotten away from the cutout and recessed look anyways.  Probably due to the same issues I mention about fitting it all and losing storage space.   The long term plan is to replace the entire transom with a third pontoon log with a built in transom and maybe even a built in tank.  Also strakes.   I found a guy in ohio that seems to really know his stuff and can build it just how I want it.   A tad pricey at around $3400 bucks though.  



Here she is with the new decking on.   Everything but the last piece is in place.   I have to order some Z channel and get some new bolts so the last piece will go in soon. 



Here is some of the color options I was looking at for flooring.



Here is some flooring and some potential sunbrella cover and bimini options.  



Here again is some flooring options.   I plan to go with the left two.   Yes two of them lol.   You'll see stay tuned.  



Seating layout 1 (If i don't put a changing room in the rear)



Seating layout 2 (with room left to incorporate a changing room at the stern)



Here is a picture of some of the blue pontoon fence paneling I got from fenceforpontoons.com
This color is gorgeous in person.   Love it so much!



Here is an image of the silver I got from the same place.





Posted By: curtiscapk
Date Posted: 05/14/2018 at 2:54pm
Awesome! can't wait!

-------------
Craig n Paula
http://www.pontoonboatforum.com/forum_posts.asp?TID=7781&title=the-floater-rebuild" rel="nofollow - THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake


Posted By: gerard143
Date Posted: 05/19/2018 at 8:46pm
Well i've made some progress over the last week.   The rain and waiting on some parts has held me up a bit.   

I now have an entire 15 foot box truck full of boat parts and my kitchen is stacked with parts too in about a 5x9 foot area.  


I have filled in all the wood imperfections with wood filler.  All except the stern-most 4x8.   That one hasn't been laid down yet as I was waiting on some 2.5x2.5x3/16x8' box stock aluminum to replace one of my cross members (the one that was cutout for motor).  I moved the Z bar crossmember that was just ahead of this cut one to the rear to keep the dimensions proper of where I needed the crossmember to end to lay a full 4x8 sheet of wood down.   Then installed the 2.5x2.5 box stock in its place.  I had to take it to work and do some machining.  I wanted slots in it for adjustability like all the other crossmember have.  Also cut some access holes for the bolts in case I need to hold them while tightening or ever remove/replace them.  Some holes I cut with a regular old hole saw but it chatters a bit.  It work with a drill press I was able to make much cleaner and to size holes with a unibit.  For cutting the slots I used an end mill bit in a mill.  Cut it like a hot knife thru butter.  

I also ordered $120 worth of hot dipped galvanized heat treated nuts, washers,bolts, etc for bolting the transom back in and a bunch of extras for when I install my third log.  Fastenal had these in grade 5 which is what the transom originally had.  Grade 8 in hot dipped was like impossible to find.  Grade 5 will be fine anyways.  

I've been researching steering options and at first I was thinking going hydraulic but I might actually go with electric steering.  Waiting to see what cost comparison is on this.  But I love all the pros about electric steering once I saw the seastar optimus system.  

Anyways the alum crossmember is completed with my mods and it is ready to go in (but rain all weekend so can't work on it).   Once that is in I can finish bolting up the transom then install the last piece of decking, fill it, sand it all and install my woven vinyl floor :-)

I also have been playing briefly with the fencing seeing how I want to remove the paneling.  I tried bending like most do but i figured maybe it would be easily just cutting the welds that held the top bar in on each panel, slide the new paneling in, then re-weld.   That was a nightmare.  I am just not anywhere near good enough at welding aluminum to mess with it.  I have a mig spool gun but no tig here.  So I guess i'll be doing the bend method. 


Here is a few more pics.... 



This photo shows the 2.5 box tubing that I bought.  Cost me $140 for the 8' piece.  It is 6061 T6 alum and should be way stronger then the Z Bar channel that came on the boat even with the slots and holes cut in it that I needed. 



Here is the 8' piece of box tubing chucked up in the mill. 



Here is some of the slots I machined in with an end mill.  These are for the mounting bolts that bolt it to the pontoon logs.  The stock crossmember have slots for adjustment and I figured i'd mock this. 



In this photo I am punching some 1" holes with a unibit for wiring runs to pass thru the crossmember in the same location the original crossmember have them.    The right most hole I punched thru with a hand drill at home and a hole saw.  Those came out a little rougher due to chatter.  That hole is replicated over each bolt hole area so I can get a ratchet in there to tighten things down and for any future access needs. 



Here is a bunch of samples of material for both the bimini top and cover.  Most sunbrella with a few pieces of Top Gun's material.   The top gun stuff without a doubt is going to be way more waterproof but the color selection is lame.   I lean towards sunbrella or sunbrella seamark which I feel is about the best there is for fade resistance and waterproofing.  


Posted By: curtiscapk
Date Posted: 05/21/2018 at 2:29pm
Fantastic!

-------------
Craig n Paula
http://www.pontoonboatforum.com/forum_posts.asp?TID=7781&title=the-floater-rebuild" rel="nofollow - THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake


Posted By: gerard143
Date Posted: 05/25/2018 at 4:52am
Well tonight I want to cry.    It was suppose to be a good day after work.  I was so excited to get my woven vinyl down.   Disaster struck.  I have the worst luck in the world I swear.  

I have one piece of the 4x8 sheets I ordered that didn't have the nicest looking face on it compared to the rest.  I wish I never used it.  It sat a bit higher then the boards next to it too and I had to do a lot of filling and sanding along the seam to try to even it out. But it got worse.  

I began to apply glue to half of the boat and then rolled out half my roll of infinity luxury woven vinyl ($1700 dollar piece of material).  That seam I spent a ton of time trying to smooth the transition was still noticeable.  But worse was a bubble in the carpet a little closer up from the seam in the middle of the board.  I peel the woven vinyl back and find that the moisture from glue (quality stuff AAT-390) had actually caused the top layer of the laminate on the board to separate and raise.  It looked like laying a 15" pen down and about 1" away laying another 8" pen down.  Couldn't believe it.  Wasn't there before the wood got moist from the glue. 

What proceeded next was essential wasting my woven vinyl because it had glue all over the back of half of the piece.  Then I spent the next 3 hours trying to atleast maybe salvage the 3 sheets of wood that I had covered by washing off the glue with a pressure washer.  I got the glue off eventually but it washed out all my filler that i had put on the wood and sanded and splintered up the wood a lot.  So tons of sanding will be required on the entire sheets now, not to mention trying to sand those high spots off and refilling all the imperfections again and sanding it all again.    Had to order another $80 in glue.   

Its 11:30pm now,  got started around 3:30.   I rethink all of this and it makes a grown man want to cry. Should have been such a happy day. All i can say is thank god infinity had sent like 10 feet extra in my roll for whatever reason.  I wound up wasting that entire 10 feet piece.   I definitely dont have enough anymore to cover the entire boat, but I can use the aqua tread imaged flooring ahead of my playpen area and use the rest of the woven vinyl roll inside the playpen area.

I'm leery about reusing these three sheets now.   I am also leery as to what if this happens again, not to mention all the work I have to redo and i figure it'll delay me from being on the water for probably another two weeks (wait on supplies, wait for days with good weather to work on it, etc) 

Below is a link to the video.  After I got the glue off I took some pics of the ripple and a little vid.  Lots of water under that ripple.   I slap my had on the deck and it oozes out.  Woulda just pushed on it but couldn't reach that far onto the deck and didnt wanna climb back up there.

If i could go back in time I probably would have just ordered marine grade tongue and groove. Just don't see any true marine grade wood out there that is pressure treated.  



After scraping the glue off the 3 sheets i had applied it too.   I tried solvent briefly but then went to water and the pressure washer.  Worked better.   



Here you can see the one rippled that occurred below the level under the right side of the word empire. This photo probably shows the height of it the best. The one of the left is worse then the smaller ripple to the right of it.  You can see the splinters that occurred on this sheet after pressure washing.  This is the sheet that was the roughest looking of the bunch.  The other two i had to pressure was didnt really splinter much.   There is something clearly different about this sheet. 



Here is a the two ripples.   It was a dark out by the time  I got done pressure washing so these are the best pics i could get with a shop light. 



another shot. 





Posted By: MYKEY
Date Posted: 05/25/2018 at 1:40pm
Hey Gerard! How's your pontoon lookin now?


Posted By: gerard143
Date Posted: 05/25/2018 at 3:10pm
Originally posted by MYKEY MYKEY wrote:

Hey Gerard! How's your pontoon lookin now?


Not good at the moment. See the post ahead of yours about my issue when I tried to glue down the vinyl to the pontoonstuff flooring. I swear I’m cursed.


Posted By: MYKEY
Date Posted: 05/25/2018 at 6:11pm
Oh wow! I didn't notice the time stamp on that one. I used the deck kit from PS (came with glue) and gray vinyl. I laid the vinyl on the deck the I fold it in half length wise, rolled out the supplied glue and repeated on the port side. Rolled it out with a roller. Came out pretty good. What glue did you use by chance?


Posted By: gerard143
Date Posted: 05/25/2018 at 8:09pm
Used same method. Aat-390 stuff infinity luxury vinyl recommends it’s real good stuff. That one 4x8 sheet really boned me.


Posted By: gerard143
Date Posted: 05/27/2018 at 5:36am
Started cleaning my rails.   Tried the pink coil cleaner some yellow stuff and real quick tried toonbrite.  All of them turned the rails white.  The rail looked absolutely horrible.  I common problem I read many encounter when trying to clean the pontoons. 

I am learning some serious lessons here.   Work on small areas and test first!!!!!  

So to try and get all that white off that made my rails look god awful I busted out the buffer and some white diamond metal polish.    It helped bring it back to normal color thank god.

I'm done using acid on the rails.   Others seem to have decent luck with it.   Me not so much.  Feel like i'll i'm doing lately is taking steps backwards.   

Anyways I got up on the deck and took a good look at the section of the one 4x8 that bubble up.  The top laminated layer was definitely bonded poorly there.   I tore the sections right off easily with my fingers in that section that had bubbled up. 

Here are some photos.     






Posted By: toonrider
Date Posted: 05/28/2018 at 12:11am
Can you remove the sheets and flip them over to use the other side? Or are you thinking of replacing the sheets? Sounds like a bummer, but you will prevail!Thumbs Up


-------------
Randy
2008 SunTracker 190
2008 Mercury 60hp Bigfoot


Posted By: gerard143
Date Posted: 05/29/2018 at 3:52am
Originally posted by toonrider toonrider wrote:

Can you remove the sheets and flip them over to use the other side? Or are you thinking of replacing the sheets? Sounds like a bummer, but you will prevail!Thumbs Up


No the other side is C face. The better side being B face wood. Lots of knots and roughness on other side.   I want to replace the one sheet plus get another sheet for my sundeck project.


Posted By: gerard143
Date 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.









Posted By: gerard143
Date Posted: 05/29/2018 at 5:09pm
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!


Posted By: gerard143
Date Posted: 06/06/2018 at 9:06pm
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. 




Posted By: gerard143
Date 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.   





Posted By: curtiscapk
Date 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.

-------------
Craig n Paula
http://www.pontoonboatforum.com/forum_posts.asp?TID=7781&title=the-floater-rebuild" rel="nofollow - THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake


Posted By: gerard143
Date Posted: 06/16/2018 at 2:55am
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. 




Posted By: gerard143
Date Posted: 06/17/2018 at 3:36am
Sanded 1 rail and 2 gates today. 7.5 hours and still not done. Craziness lol.


Posted By: curtiscapk
Date Posted: 06/18/2018 at 6:55pm
Email notification is there now!

-------------
Craig n Paula
http://www.pontoonboatforum.com/forum_posts.asp?TID=7781&title=the-floater-rebuild" rel="nofollow - THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake


Posted By: gerard143
Date 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 :-)


Posted By: curtiscapk
Date Posted: 06/19/2018 at 2:24pm
It's there for everyone now.

-------------
Craig n Paula
http://www.pontoonboatforum.com/forum_posts.asp?TID=7781&title=the-floater-rebuild" rel="nofollow - THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake


Posted By: gerard143
Date 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.   






Posted By: curtiscapk
Date 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?


-------------
Craig n Paula
http://www.pontoonboatforum.com/forum_posts.asp?TID=7781&title=the-floater-rebuild" rel="nofollow - THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake


Posted By: gerard143
Date Posted: 06/25/2018 at 10:45pm
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.


Posted By: gerard143
Date 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!


Posted By: curtiscapk
Date Posted: 07/02/2018 at 2:17pm
Clap

-------------
Craig n Paula
http://www.pontoonboatforum.com/forum_posts.asp?TID=7781&title=the-floater-rebuild" rel="nofollow - THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake


Posted By: Bansil
Date Posted: 07/03/2018 at 11:48am
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


Posted By: gerard143
Date Posted: 07/03/2018 at 1:06pm
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.  

 


Posted By: gerard143
Date Posted: 07/04/2018 at 1:55pm
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.







Posted By: curtiscapk
Date Posted: 07/05/2018 at 3:15pm
That Blue is sweet! Keep em coming!

-------------
Craig n Paula
http://www.pontoonboatforum.com/forum_posts.asp?TID=7781&title=the-floater-rebuild" rel="nofollow - THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake


Posted By: gerard143
Date Posted: 07/10/2018 at 3:31pm
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)






Posted By: curtiscapk
Date Posted: 07/10/2018 at 4:10pm
Can't wait!

-------------
Craig n Paula
http://www.pontoonboatforum.com/forum_posts.asp?TID=7781&title=the-floater-rebuild" rel="nofollow - THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake


Posted By: m and m
Date Posted: 07/11/2018 at 3:31am
build is looking great!  Keep up the good work.



-------------
"AttaBoy" Award for Dec 2010
Mooresville, NC
88 Tracker Bass Buggy 20'
88 Mercury 60 hp


Posted By: gerard143
Date 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?



Posted By: curtiscapk
Date Posted: 07/13/2018 at 9:28pm
Looks Awesome! send close up shots of you cushions to support!

-------------
Craig n Paula
http://www.pontoonboatforum.com/forum_posts.asp?TID=7781&title=the-floater-rebuild" rel="nofollow - THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake


Posted By: gerard143
Date 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!


Posted By: curtiscapk
Date Posted: 08/22/2018 at 4:19pm
Let's see em!

-------------
Craig n Paula
http://www.pontoonboatforum.com/forum_posts.asp?TID=7781&title=the-floater-rebuild" rel="nofollow - THE FLOATER Rebuild
94 Party Barge 24' 115 merc
22mph
OP KS
Truman Lake



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