Scott Farris
Well-known member
The previous build post left the boat stuffed with flotation, ready for decking. As most projects go it's taking three times as long as I expected but progress is being made.
First step is cutting the panels out that will make up the deck. The sides are the two 10' X 10" strips sheared off by the aluminum supplier. The bow was cut from the left over piece from the last decking project. In between was cut from the remaining 28" X 10' sheet.
View attachment bow on deck start.JPG
Note the new grab handles on the stern. With the deck there is nothing to grab so handles are needed.
View attachment deck start stern.JPG
I could have sworn I took a number of riveted deck pictures, but as I search through the photos and down size them, there are no shots at all, other than when taken to show the jet conversion. This shot is the best of the deck, but it is taken to show both the motor board and the aft deck fitting. The top of the board down to the bottom is 22".
View attachment fitting stern deck.JPG
The aft deck was left off until the motor was converted, then I needed access to mount the bilge pump and the battery box frame. Once the deck is mounted I don't want to have to take it off again. This shot also shows the motor board sandwich, 2 sheets of 3/4 ply epoxied together wrapped in .06 aluminum fit between two 2X2 X .125"aluminum angles. For the motor to clear the boat's aft rail I had to add another 3/4 ply board to the outside top portion. Once the overall height is finalized I plan on capping with another sheet of aluminum and 5200 to keep water out of the sandwich.
View attachment Jetmountedstarbaftquaarter.JPG
The shallow water money shot: The leading edge of the intake foot is roughly 1/4" below the boat's bottom.
View attachment Jet from the stern.JPG
In the photo above - new bunks. I took an afternoon off to replace the bunks. I was planning on it anyway but when I dropped the boat off on the lawn I found the back end of one of the bunks rotted off under the carpet. I redid the bunk mounts and hardware and installed 6' 7" long pressure treated 2" X 6" boards with slick sticks on them to ensure wood never touches the aluminum. I did this on my Starcraft's trailer and it's coming up on fifteen years and they are in great shape. A new winch was bolted in place in place of the tiny old rusty one. I am not fond of the axle, but that may be next years project. This one should do find for the season.
With the aft deck still off, this afternoon was mount the bilge pump and create the battery box mount. The bilge pump will discharge straight up through the deck as the hose enter a 90 degree barb. I have plans to armor the discharge barb up if needed. I'm hoping it will sit tight in the deck penetration. For gas hose and motor wire I purchased a vinyl boot to protect their deck penetration.
View attachment batterybox.JPG
And Dave (aka: Colonel Popcorn), I doubt you can tell from the pictures, but I did switch out to riv-nuts for both the battery switch mounting plate and the electrical panel; I had to get into the panel and the rivets drilled out nicely but I realized that while I have a screw driver in my boat toolbox, I don't have a drill and pop rivet gun in the field. Thanks for making me think!
Tomorrow is supposed to rain so maybe I will actually get the aft deck on.
Scott
View attachment fitting stern deck.JPG
First step is cutting the panels out that will make up the deck. The sides are the two 10' X 10" strips sheared off by the aluminum supplier. The bow was cut from the left over piece from the last decking project. In between was cut from the remaining 28" X 10' sheet.
View attachment bow on deck start.JPG
Note the new grab handles on the stern. With the deck there is nothing to grab so handles are needed.
View attachment deck start stern.JPG
I could have sworn I took a number of riveted deck pictures, but as I search through the photos and down size them, there are no shots at all, other than when taken to show the jet conversion. This shot is the best of the deck, but it is taken to show both the motor board and the aft deck fitting. The top of the board down to the bottom is 22".
View attachment fitting stern deck.JPG
The aft deck was left off until the motor was converted, then I needed access to mount the bilge pump and the battery box frame. Once the deck is mounted I don't want to have to take it off again. This shot also shows the motor board sandwich, 2 sheets of 3/4 ply epoxied together wrapped in .06 aluminum fit between two 2X2 X .125"aluminum angles. For the motor to clear the boat's aft rail I had to add another 3/4 ply board to the outside top portion. Once the overall height is finalized I plan on capping with another sheet of aluminum and 5200 to keep water out of the sandwich.
View attachment Jetmountedstarbaftquaarter.JPG
The shallow water money shot: The leading edge of the intake foot is roughly 1/4" below the boat's bottom.
View attachment Jet from the stern.JPG
In the photo above - new bunks. I took an afternoon off to replace the bunks. I was planning on it anyway but when I dropped the boat off on the lawn I found the back end of one of the bunks rotted off under the carpet. I redid the bunk mounts and hardware and installed 6' 7" long pressure treated 2" X 6" boards with slick sticks on them to ensure wood never touches the aluminum. I did this on my Starcraft's trailer and it's coming up on fifteen years and they are in great shape. A new winch was bolted in place in place of the tiny old rusty one. I am not fond of the axle, but that may be next years project. This one should do find for the season.
With the aft deck still off, this afternoon was mount the bilge pump and create the battery box mount. The bilge pump will discharge straight up through the deck as the hose enter a 90 degree barb. I have plans to armor the discharge barb up if needed. I'm hoping it will sit tight in the deck penetration. For gas hose and motor wire I purchased a vinyl boot to protect their deck penetration.
View attachment batterybox.JPG
And Dave (aka: Colonel Popcorn), I doubt you can tell from the pictures, but I did switch out to riv-nuts for both the battery switch mounting plate and the electrical panel; I had to get into the panel and the rivets drilled out nicely but I realized that while I have a screw driver in my boat toolbox, I don't have a drill and pop rivet gun in the field. Thanks for making me think!
Tomorrow is supposed to rain so maybe I will actually get the aft deck on.
Scott
View attachment fitting stern deck.JPG