1966 Boston Whaler 13 Restoration

My 1966 Boston Whaler 13 restoration. This is definitely an Extreme DIY project! I’ll be restoring a 1966 Boston Whaler 13 with a 1981 Johnson 40hp outboard.

Over all condition of the interior is fair to bad. Consequently, I’ll be spending a lot of time with the interior. Correcting delamination and removing several coats of marine paint along the way. The hull is in fairly good condition. Other than patching a few holes there will be mostly sanding required. After that,I’ll apply a sealer and two part polyurethane paint using the roll and tip method.

I’ll be doing an assessment of the Johnson 40hp outboard as well. Hopefully, I will be able to use it as part of the restoration. I hope to eventually have a nice video of the vintage boat running on the lake!

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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Replace a Johnson Evinrude VRO Oil Pump with a Standard Fuel Pump

Why Remove the VRO Oil Pump? Running an older outboard can present some challenges. One of them is the constant worry of having the VRO oil pump go out on you. Many boaters elect to bypass a Johnson or Evinrude oil pump. There is a ton of information in the Internet on how to do …

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Cleaning Fixed Idle Jet Passage on an Outboard Carburetor

After rebuilding these carburetors I still had a rough idle. I took the carbs back off and removed the access plug and carburetor lead shot to clean the idle circuit out completely. I also found a good alternative to the expensive “carburetor lead shot plug” from OMC Johnson/Evinrude. This is my second go around with …

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How to Replace an Outboard Thermostat

So far I’ve done a number of things to restore this old outboard to life. Before going any further though, I want to make sure there is adequate cooling for this engine. There are two things I’ll tackle to do this. First, I’ll replace the outboard thermostat. This engine hasn’t been in run on a …

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