Boat Restoration and Repair

Doing boat restoration has become an ongoing hobby for me. Each project seems to be more complex than the last. I like that progression. It broadens my skill sets and prepares me for the next, which may be more difficult.

2005 Sea Boss Restoration

My last boat restoration involved a lot of wiring projects. I added a nice  sound system with a high power amp. I didn’t need to but I really wanted to make this boat stand out. To that end, I also added blue led interior lighting to it. In order to do that I had to add a lot of auxiliary wiring as well as switches and power panels. I also learned to leave drag string inside the hull for future wiring projects. I also learned a lot about fiberglass repair and gel coating. There was a large gash in the upper part if the boat. Thankfully, not in the hull.

Wahoo 18 CC Restoration

Before that I restored a Wahoo center console 180. That was really an education for me. I re-pwoered that boat with a used Mercury engine. It originally had an Evinrude. I learned the hard way that I had to run all new controls on that boat to match the engine. Here’s a link to that article. Wahoo Restoration

1966 Boston Whaler 13 Restoration

I’m on my third restoration project, a 1966 Boston Whaler 13. This one is going to be a challenge. The hull is in great condition. However, the inside shell needs a lot of work. There’s several layers of old paint as well as some fiberglass de-lamination that needs to be corrected. Not only that, but there are sections of the non-skid flooring that need to be repaired (ore entirely removed). On top of that, the engine, a 1988 Johnson 40HP hasn’t been run in over 20 years. I’ll be spending  a lot of time getting this seaworthy but am looking forward to the challenge!

How to Roll and Tip Topside Boat Paint – Boston Whaler Restoration Part 8

I finally have the topside finished! Watch as I go through entire process of getting the topcoat of polyurethane boat paint on. I used Total Boat Topside WetEdge in Classic Boston Whaler Blue. It’s a single part polyurethane marine paint and simple to use. Most of this was rolled on but for the most obvious …

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Fiberglass Paint Primer and Sanding – Boston Whaler Restoration Part 7

Getting the interior of this Boston whaler ready for a finish coat of fiberglass paint has been a challenge. There was a lot more defects that really were unnoticeable until you started Digging in. The first hurdles were the large hole in the anchor locker, rebuilding the transom and the delamination in the bow . …

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Gelcoat and Fiberglass Repair of Large Missing Areas – Boston Whaler Restoration – Part 6

While grinding out a few larger cracks, I discovered that what I thought was a large crack on the bulkhead was actually a large chunk of fiberglass and gelcoat that had been glued back in. So It looked like I needed to do a gelcoat repair. This isn’t necessarily complicated or hard. There are several …

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Fiberglass Transom Repair – Boston Whaler Restoration – Part 5

I’ll be writing about how to do a clean transom repair. A previous owner modified the transom so that a steering rod on a newer motor would work correctly. These old (1966) Whaler 13’s had a lowered (15″) transom. A pulley and cable system originally steered the boat. When past owners upgraded their engines, one …

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Small Fiberglass Hole Repair – Boston Whaler Restoration – Part 4

If you restore fiberglass boats, fiberglass hole repair is going to be one of the tasks you face. Many folks will just fill in the hole, sand it smooth and call it a day. The problem with that is that those plugs will eventually work themselves loose. Think about the vibrations a boat hull is …

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Anchor Locker Fiberglass Repair – Boston Whaler Restoration – Part 3

One aspect of this Whaler 13 restoration that I’ve been anticipating is repairing the large hole in the anchor locker. This is a medium to large endeavor in fiberglass repair. I’ll be using epoxy resin to lay down the fiberglass mats. I’ve also already used “excess” epoxy resin from other repairs to create a solid …

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Delamination Fiberglass Repair – Boston Whaler Restoration- Part 2

This old Boston whaler has some severe fiberglass delamination on the bow. There are a number of techniques that can be used to do a delamination fiberglass repair. I decided to go with injecting an epoxy based resin. Identifying the obvious spots is pretty easy. But, you also have to take the time to find …

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Boston Whaler Restoration – Norman Pins (Cleats) Part 1

I’m getting ready to start the hull and interior renovation on my 1966 13′ Boston Whaler. My plan is to start with the interior, which needs the most work. Before I get started with that, I want to remove the Whaler norman pins. This will give me access to the fiberglass and gel coat that …

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1988 40HP Johnson Shift Linkage Location

Finding the Johnson Shift Link Location! A smart approach to any task is planning out the steps to complete it ahead of time. I planned on doing that when dropping the lower unit for the first time. There was just one drawback, I couldn’t find the Johnson shift linkage location!This happened to me recently when …

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Remove an Outboard Lower Unit with a Stuck Drive Shaft

After sinking a significant amount of time and money into this motor, I wanted to do one more thing before starting it up. IT had shown a weak stream of coolant when I had run it before, so I figured a new impeller would be the next think to do. I went through the normal …

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