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1996 Sun Tracker Rebuild

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=8807
Printed Date: 07/22/2018 at 1:18pm
Software Version: Web Wiz Forums 11.01 - http://www.webwizforums.com


Topic: 1996 Sun Tracker Rebuild
Posted By: Scott573
Subject: 1996 Sun Tracker Rebuild
Date Posted: 08/22/2017 at 2:45am
Let me begin by saying this forum is amazing.  I've spent the last 2 days walking through each and every rebuild post...  So much great information!  

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

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

Scott










Replies:
Posted By: curtiscapk
Date Posted: 08/23/2017 at 7:07pm
Awesome neighbor! Check out my rebuild in my sig. Close to the same toon!

-------------
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: Scott573
Date Posted: 08/24/2017 at 2:28am
Wow, you're right!  Jealous you're in the water but hope to be there by spring next year.  I can picture us sitting on our PS seats over the winter too!?!?!


Posted By: Scott573
Date Posted: 09/05/2017 at 11:26pm
So a very productive labor day weekend.  Was able to remove fencing, and get decking down to the condition shown below.  

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

Scott



Filled up a 7 yard dumpster!!!








Posted By: curtiscapk
Date Posted: 09/06/2017 at 2:51pm
I used vice grips others have used a sawzall.
 


-------------
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: Scott573
Date Posted: 09/07/2017 at 11:54am
Appreciate your reply.  Were you able to remove the wood around first?  Looks like it in the picture but wanted to confirm.

Scott


Posted By: curtiscapk
Date Posted: 09/07/2017 at 4:18pm
hole saw around all the screws then vice grips....

-------------
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: Scott573
Date Posted: 01/28/2018 at 5:57pm
Quick question for the forum on fencing panels:  Ours is in pretty good shape but with older decals in tact.  Would love a poll of new fencing panels vs. sand and paint.  Thanks in advance!  As an update, finally have most of the decking off with plans to grind rusted bolts this week.  I'm jealous of all the rebuild project owners that have garages!!!  

Scott


Posted By: Barnmb7117
Date Posted: 01/28/2018 at 6:37pm
I think it comes down to cost. I would love to replace mine with blue but it would run between 3 and 4 hundred to replace it. Plus the cost of new decals.and to paint it less then a hundred plus decals but I have a compressor and paint guns already.
  I did 2 rebuild in my driveway but it was summer.


-------------
Mike
1993 Tracker fishing barge 21
2015 Evinrude pontoon series 90 hp
Summer - On the wolf River Weyauwega, WI
Winter- Chicago, IL


Posted By: Scott573
Date Posted: 01/29/2018 at 1:21am
Thanks Mike for your reply.  I'm torn but leaning towards putting the $295 into the new fence panels.  Either way is tedious but I don't have any painting supplies so...  On a positive note I finally removed all of the old wood deck today.  I pray that process is the most difficult of this rebuild as my hands are hurtin!!!! :-)




Posted By: Scott573
Date Posted: 01/29/2018 at 1:23am
Craig, hope all is well!  I see you have the same black epoxy like material on the stringers.  Out of curiosity how did you remove?  Thanks!

Scott


Posted By: curtiscapk
Date Posted: 01/29/2018 at 2:39pm
Hey Scott,


I just scraped it off and left whatever was still there. Used new roll of seal so it really didn't matter. I started my rebuild at the lake lot in March of 2013. With a generator for power!


-------------
Craig n Paula
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: Scott573
Date Posted: 01/31/2018 at 10:49pm
Thanks Craig.  Much appreciated!  I just have on one or two stringers and will just plan to try and get it as flat as possible.  Pulled 3 of 5 fence panels last night...  Easy to pull but nervous how the new will go in.  More pics to come.




Posted By: Barnmb7117
Date Posted: 02/01/2018 at 4:24pm
take your time with the panels extra hands will help.


-------------
Mike
1993 Tracker fishing barge 21
2015 Evinrude pontoon series 90 hp
Summer - On the wolf River Weyauwega, WI
Winter- Chicago, IL


Posted By: Scott573
Date Posted: 02/02/2018 at 6:50pm
Thanks Mike, agreed on taking time, pretty nervous for the curved panels...  Hoping to get one cleaned this weekend and give it a try


Posted By: Scott573
Date Posted: 02/03/2018 at 3:32pm
Next question for the group.  Really appreciate all of the help thus far!  Have been using the Mac's aluminum brightener to clean the existing rub rails.  Pretty simple process:  Spray, let foam up, rinse with cold water, then scrub the remaining areas that didn't take on round 1.  Works pretty well as long as there is no build up of grime on the corners and other surfaces.  Moving on to the fencing...  

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

Appreciate the advice as always!

Scott






Posted By: Scott573
Date Posted: 02/11/2018 at 3:09pm
Made progress last week.  Following Craig's advice I used WD 40 and vice grips to remove 2/3s of the countersunk screws.  For the remaining that were too rusted out I ground them down flat.  The tar was brutal to scrape of but it's close enough!  Finally ready for new decking; now just have to figure out the delivery logistics.







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



Received console and gauges this week.  Planning to cut holes and install them and a new head-unit tonight.  Cheers!


Posted By: curtiscapk
Date Posted: 02/12/2018 at 2:24pm
Sweet! do you know anyone that owns a business in parkville that has a dock??? If not let me know. You should be able to use my company's but we're downtown....PM me if you need to.


 


-------------
Craig n Paula
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: Scott573
Date Posted: 02/12/2018 at 5:48pm
Craig,

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

Talk soon,

Scott


Posted By: chatfield1
Date Posted: 02/12/2018 at 6:10pm
Hello there! 

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

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

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

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

-Cassie


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

Thanks again, Scott


Posted By: chatfield1
Date Posted: 02/12/2018 at 7:00pm

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

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

and the rivets on this site..

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

They matched perfectly. You can get a hand rivet for about 20 bucks, not hard to squeeze its very easy.


Posted By: Scott573
Date Posted: 02/12/2018 at 7:41pm
Awesome, panels look great.  I ordered my fencing from the same website.  Did you have to cut to height or did it match perfectly?  That's my only concern as I have to "cut down" each panel to be the correct height.  Also did you cut by scoring and bending or with shears?  


Posted By: chatfield1
Date Posted: 02/12/2018 at 7:56pm
Thank you! I liked the way it turned out for sure.

So the height did not match everywhere we had to make cuts both ways. Your fencing may be different but for mine I had to cut the height for all but 2 pieces. The website said just use a knife to score and bend off. That’s what we did, scoring it sucks you need to go over it about 3 times for it to make a clean snap. Make sure to change your blade for ever new piece, it take a really sharp knife. Once you get in the groove though and understand what you are doing it gets easier.


Posted By: Scott573
Date Posted: 02/12/2018 at 8:30pm
Excellent, that's the exact situation we're going to be in with regards to making two cuts per every section...  Just ordered the rivets!  Let me know if you can think of any other helpful hints in the process (like did you start with one rivet in the upper corner, what spacing did you use, what kind of two-sided tape did you get, etc.).  Thanks again for the advice!  Scott


Posted By: chatfield1
Date Posted: 02/12/2018 at 9:25pm
The tape I used is on the website you got your panels from. 

As far as the rivets I didn't start at any certain spot (the tape holds it mostly in place) I just about every 3-4 inchs a rivet. Except for the corners I needed extra on those you'll see when you do it but the corners was more so every 2 inches.


Posted By: Scott573
Date Posted: 02/13/2018 at 2:16am
Started work on the console tonight.  First we taped the templates to the base, then drew the outline for the cuts but left a generous amount of room to "fine tune."  Then drilled several holes to allow for a starting point and finished off the cuts with a saw zaw.  Cut back all of the shavings afterward with a sharp razor blade.  Pretty easy but just have to take things slowly to not over cut.  The accessory panel is especially tedious as there is not much room on either side for a mistake.


















Posted By: PontoonMike
Date Posted: 02/15/2018 at 2:35pm
Looks awesome Scott! Great job on the gauges installation. 

-------------
Mike K
PontoonStuff.com
Social Media Manager
Phone: 877-295-9522


Posted By: curtiscapk
Date Posted: 02/15/2018 at 3:45pm
Nice! at least you have the new console! I did all my work through an 18 x 12 door!








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

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

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

Scott










Posted By: Scott573
Date Posted: 02/19/2018 at 8:19pm
Was able to take advantage of the nicer weather in Kansas City this weekend and got the decking installed.  Not warm enough for the carpeting to adhere but still a big step!  

Couple of comments/lessons learned for those that may read this in the future:

1.  Take pictures (and measurements), take pictures (and measurements), take pictures (and measurements).  If it weren't for the picture below I would have screwed up the decking and not left a 5-1/2" lip off the front of the boat.  



When I started putting the wood on I couldn't get the sections to land on the stringers right.  After I found the picture I realized that the boat had shifted forward on the trailer!?!?!  That meant I had to drive it to the lake, put in water and push back ;-).......  Took an extra 30 minutes but it was worth it.

2.  We used all but 4 (of the 100) countersunk screws so I think it would be good to plan those out vs. using at will.  Still worked out well but could have stunk to run out!

3.  Buy some marine sealant just in case.  We had a piece of wood that was a little crooked on one end which created a 1/8" gap between two of the boards.  Put some foam filler and sealant and worked just fine.










Posted By: curtiscapk
Date Posted: 02/20/2018 at 2:26pm
nice work!

-------------
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: chatfield1
Date Posted: 02/21/2018 at 3:50pm
Looking really good Scott! 


Posted By: Scott573
Date Posted: 02/21/2018 at 9:01pm
Thanks guys!!!!  April/May is rapidly approaching!!!

Scott


Posted By: Scott573
Date Posted: 03/11/2018 at 1:53pm
Quick question for the group.  What type of speaker wire do most use?  Marine or just regular 16/18 ga and minimize any connections in a wet/dry interface?  I'm planning to run all wiring in 1/4" corrugated tubing.  Thanks in advance!

Scott


Posted By: curtiscapk
Date Posted: 03/12/2018 at 1:31pm
I used regular for speakers. Actually plan to mount 2 more  speakers under sun deck, facing out the rear for floating,Big smile

-------------
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: Barnmb7117
Date Posted: 03/13/2018 at 5:02pm
I used marine..


-------------
Mike
1993 Tracker fishing barge 21
2015 Evinrude pontoon series 90 hp
Summer - On the wolf River Weyauwega, WI
Winter- Chicago, IL


Posted By: Scott573
Date Posted: 03/19/2018 at 9:58pm
Lot's to update as we've had some good weather as of late.  Let's start with the fencing panels.  As mentioned before, we used Mac's aluminum brightener to clean the fencing which worked great.  Our fencing was originally attached to the paneling by a metal lip which is pretty common.  That lip broke off in multiple places so we ended up removing it.  After doing so it actually provided a perfect "indented" template to put the new paneling "inside." 


 


We used blue colored rivets, and bought aluminum paneling from Pontoonfence (ordered 60’ roll, had 5-7 ft left over)

 

Our technique to cut was as follows:

 

Used a new blade for each cut, used bottom of fencing as a guide


 


Ran through cut at least 3-4 times until we started seeing some aluminum shavings come up

 

To make the break, we grabbed a 2x4, put on “good side” then bent the bad side towards it.  After bending back to flat in most cases it would break then

 





We put rivets approximately every 4-6” which seemed to work from a rigidity perspective.

 

The carpet was pretty easy to install.  Was able to use a friend’s heated garage and let sit for 24 hours at 65 degrees.  I did like most have mentioned, roll out completely, fold lengthwise and apply adhesive one half at a time with a paint roller.  After a few minutes you get the hang of it as the adhesive is pretty thin, so you just need to work it around in a way that spreads evenly and with enough thickness.  We didn’t have the issue that others have discussed with it drying quickly but that might have been due to the temperature in the room.  Once down we used a carpet roller (100 lb) to remove wrinkles and bubbles.

 

After that, we finally got to the fun stuff!!!!  

 






 

 

Scott



Posted By: curtiscapk
Date Posted: 03/20/2018 at 1:40pm
wow! that looks great! Nice job!

-------------
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: Scott573
Date Posted: 03/21/2018 at 12:59am
Thanks Craig!!


Posted By: curtiscapk
Date Posted: 03/21/2018 at 1:12pm
you need to make a trip to Truman!

-------------
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: Barnmb7117
Date Posted: 03/21/2018 at 4:32pm
Hi Scott, it is looking good.


-------------
Mike
1993 Tracker fishing barge 21
2015 Evinrude pontoon series 90 hp
Summer - On the wolf River Weyauwega, WI
Winter- Chicago, IL


Posted By: Barnmb7117
Date Posted: 03/21/2018 at 4:33pm
the rebuild looks really good.


-------------
Mike
1993 Tracker fishing barge 21
2015 Evinrude pontoon series 90 hp
Summer - On the wolf River Weyauwega, WI
Winter- Chicago, IL


Posted By: Scott573
Date Posted: 03/25/2018 at 10:06pm
Craig and team,

Any tips on wiring your head unit?  Did you hook up to one of the accessory switches to turn on and off or an ignition switch?  As far as power goes I have the power cable that came with the PS wiring harness but not sure if it's large enough to power all or not...  Only powering an amp, head unit & lighting but I think the amp might require 4 ga.  Also just bought a distribution block to help but still curious on the ignition, etc.

Any help would be greatly appreciated!!!! 

Scott


Posted By: Scott573
Date Posted: 03/26/2018 at 1:59pm
Also, any recommendations for a ignition switch? 


Posted By: curtiscapk
Date Posted: 03/26/2018 at 2:19pm
Originally posted by Scott573 Scott573 wrote:

Craig and team,

Any tips on wiring your head unit?  Did you hook up to one of the accessory switches to turn on and off or an ignition switch?  As far as power goes I have the power cable that came with the PS wiring harness but not sure if it's large enough to power all or not...  Only powering an amp, head unit & lighting but I think the amp might require 4 ga.  Also just bought a distribution block to help but still curious on the ignition, etc.

Any help would be greatly appreciated!!!! 

Scott

I tapped mine into main  always hot wire on the harness. I don't have an amp. I use a separate battery for all my accessories (PS Harness). 


-------------
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: curtiscapk
Date Posted: 03/26/2018 at 2:22pm
Originally posted by Scott573 Scott573 wrote:

Also, any recommendations for a ignition switch? 

got mine off ebay... I guessed yours as a 94 like mine..... here's a google search


https://www.google.com/search?q=1994+tracker+40+hp+ignition+switch&rlz=1C1GGRV_enUS751US752&oq=1994+tracker+40+hp+ignition+switch&aqs=chrome..69i57.14550j0j7&sourceid=chrome&ie=UTF-8




-------------
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: curtiscapk
Date Posted: 03/26/2018 at 2:24pm
www.google.com/search?q=1994+tracker+40+hp+ignition+switch&rlz=1C1GGRV_enUS751US752&oq=1994+tracker+40+hp+ignition+switch&aqs=chrome..69i57.14550j0j7&sourceid=chrome&ie=UTF-8

-------------
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: curtiscapk
Date Posted: 03/26/2018 at 2:27pm
Sorry for the link. Here's some pics of Ignition and gauge wiring








-------------
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: Scott573
Date Posted: 03/26/2018 at 2:30pm
Thanks Craig as always.  I'm in an odd situation in that our lake only allows electric outboards.  Just bought a Torqueedo 4.0 Cruise which will require 4 12V deep cycles.....

That said, after some research, I think I'm going to add another deep cycle for accessories, bring a 4ga power from it to a distribution box in the console (my amp requires 4 ga), then go from there to the accessories panel and head unit.  

Question:  Is it crazy to not have an ignition (assuming the electric motor has it's own switch) but add a master switch just upstream of the distribution box as a kill switch?

Thanks so much,

Scott


Posted By: curtiscapk
Date Posted: 03/26/2018 at 3:55pm
kill switch should be fine. you on Houston Lake?

-------------
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: Scott573
Date Posted: 03/26/2018 at 7:05pm
10-4, we're on Riss Lake


Posted By: curtiscapk
Date Posted: 03/26/2018 at 8:43pm
holy stuff! I used to sneak into Riss at night from the cemetery all camo'd out LOL! I caught a bass so big a cop heard it splashing! He never could find me though!

-------------
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: Scott573
Date Posted: 04/24/2018 at 2:23pm

Greetings all!

 

I’ll try to focus this post on our electrical systems as it was one of my biggest fears!  Let me begin by stating that our situation is a little different in that our lake restricts to electric motors only.  So we don’t have a conventional ignition switch wiring diagram like most.  For us we basically have two electrical systems:  One for the electric outboard motor (four 12V deep cycle batteries) and one for the accessories (one 12V deep cycle battery for lights, stereo, horn, etc.).  We also connect our forward trolling motor to the accessories system. 

 

Wiring:  I purchased the PS wiring kit and pre-wired gauges/electrical panel which I HIGHLY recommend.  Extremely easy to install and saves so much time not having the make all of the daisy chain connections yourself.  To shield from nicks and other damage under the boat we purchased plastic “conduit” from a local Oriely’s auto parts.  We purchased an amplifier to add a little juice to our speakers which meant we had to run larger power cabling (4ga) than included in our kit to power the accessories system.  Bought our 4ga wire from bestboatwire.com which as mentioned by others is the cheapest place around for bulk marine wire.  For an in-line fuse we found a really handy terminal block fuse (from same website).  We still used a lot of the 12ga power and ground wire supplied in the kit downstream of our distribution block described in more detail below.  All wire purchased (power, speaker, etc) was tinned to prevent from corrosion.  We also used GB Ox guard before making every connection and heat shrink wire connectors wherever possible.

 

Motor Electrical System:  The electric outboard motor and batteries are one self-contained system in that the batteries are connected in series that run to the motor only.  There is a throttle control cable that spans from the motor to the throttle mounted on the dash.  It has a power button to turn the motor on and off.  The toughest part of this process was running the wiring in series from the motor to batteries to kill-switch.  Won’t waste everyone’s time as it’s probably not very common to use an electric motor but let me know if you have any questions when reading this in the future.

 


 

Accessories Electrical System:  One challenge (as noted above in this post) is that the “accessories system” needed a way to be turned on and off and also have adequate protection.  To accomplish this we added two components.  The first is an on/off kill switch from Blue Seas Marine (red in picture) which isolates the system and thus acts as an ignition switch for the accessories system.  The second is a distribution block, which was also purchased from Blue Seas Marine which accepts power from the 12V battery downstream of our on/off switch and then distributes to the individual accessory components (gauges, rocker switches, radio and amplifier).  Each have their own independent fuse and we added a fuse to the battery connector.  Doesn’t look extremely pretty in this picture but everything is secure and as neat as we could get!

 




 

All of our batteries were Interstate deep cycle marine batteries and our battery chargers were ProMarine 20 amp 3 bank chargers.  We connected both chargers to a power strip which feeds into a nifty waterproof Minnkota power port to connect to dock power (shown in white below).  Below the port is our kill switch (also Blue Seas) for the electric motor.


 


Lastly, we were able to install our new PS bimini top which was actually really simple!!  Have been really impressed with the quality of everything from pontoon stuff.  




Planning to put in the water this weekend and already have the bottle of wine and playlist picked out.  Fingers crossed!


Scott 

 



Posted By: Scott573
Date Posted: 04/29/2018 at 10:14pm
And we're done!!!






Posted By: toonrider
Date Posted: 04/29/2018 at 11:35pm
I have been following your rebuild Scott, very nicely done! Looks Great!Thumbs Up


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


Posted By: curtiscapk
Date Posted: 04/30/2018 at 2:18pm
AWESOME BUDDY! It rides high without a (motor) on it.Big smile

-------------
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: Scott573
Date Posted: 04/30/2018 at 2:38pm
Originally posted by toonrider toonrider wrote:

I have been following your rebuild Scott, very nicely done! Looks Great!Thumbs Up

Thanks!  Much appreciated!


Posted By: Scott573
Date Posted: 04/30/2018 at 2:41pm
Originally posted by curtiscapk curtiscapk wrote:

AWESOME BUDDY! It rides high without a (motor) on it.Big smile

Thanks Craig, when we were cleaning the logs we noticed that it did in the past too based on the waterline.  Our max speed is 11 mph so just need her to float Wink.




Posted By: curtiscapk
Date Posted: 04/30/2018 at 3:05pm
Shocked 11'S AWESOME! My 115 maxes at 22 on it's best day!

-------------
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: 05/02/2018 at 12:33pm
Turned out great and very pretty Thumbs Up


Posted By: Scott573
Date Posted: 05/02/2018 at 4:32pm
Originally posted by Bansil Bansil wrote:

Turned out great and very pretty Thumbs Up

Thanks!! Much appreciated!


-------------
Scott
1996 Suntracker Fun Fish 200
Parkville, MO



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