1985 Challenger 25 Makeover (continued)

Repair or modification of Boston Whaler boats, their engines, trailers, and gear
peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

1985 Challenger 25 Makeover (continued)

Postby peteinsf » Fri Jul 29, 2016 7:22 pm

Hi All,

Work continues on the Katmai NP Challenger.

Old Forum: http://continuouswave.com/ubb/Forum3/HTML/021226.html

Some in-line photos from lost links...

Starting place.

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peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Fri Jul 29, 2016 7:26 pm

Continued...

Interlux2000 after grinding out cracks.
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Sitcky 1985 3m non-skid removal (tedious)
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peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Fri Jul 29, 2016 7:29 pm

5 inch transom extension idea.

Old forum: http://continuouswave.com/ubb/Forum3/HTML/021240.html

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Last edited by peteinsf on Fri Jul 29, 2016 8:13 pm, edited 2 times in total.

peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Fri Jul 29, 2016 7:38 pm

Continued...

Motors arrive
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and get mounted.
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peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Fri Jul 29, 2016 7:46 pm

Awlgrip and bottom paint next...
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peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Sun Jul 31, 2016 12:47 pm

This week was priming all of the exposed areas where I removed the original paint around corroded areas. Also the aluminum deck was glued to the hull, screws set and then covered over...

Original Deck:

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peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Sun Jul 31, 2016 12:49 pm

Deck glued down.

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MerchantMariner
Posts: 1
Joined: Sun Aug 07, 2016 1:28 pm

Re: 1985 Challenger 25 Makeover (continued)

Postby MerchantMariner » Sun Aug 07, 2016 1:42 pm

Hey looking great. Nice job. You are an inspiration!

nes4pres
Posts: 4
Joined: Thu Aug 04, 2016 8:37 pm

Re: 1985 Challenger 25 Makeover (continued)

Postby nes4pres » Mon Aug 08, 2016 4:15 am

Looks real good. What is the shaft length of the Evinrude engines? Did you extend the transom?

jimh
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Re: 1985 Challenger 25 Makeover (continued)

Postby jimh » Mon Aug 08, 2016 10:29 am

The details of the transom can be seen clearly in the several images above. The insert into the original notched transom that provides five-inches of higher splash well height does not appear to be attached to the original hull. It looks like it is held in place by the aluminum riser brackets holding the engine, and its thickness to much too small to be a structural support for engines of 500-lbs or more.

peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Fri Sep 02, 2016 11:31 am

New tank arrives...
Attachments
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Acseatsri
Posts: 149
Joined: Tue Oct 20, 2015 8:46 am

Re: 1985 Challenger 25 Makeover (continued)

Postby Acseatsri » Fri Sep 02, 2016 1:55 pm

The engines look like they're thru-bolted into 1/2" thick x 2 x 4 aluminum L-brackets, the bottom bolts going thru the original transom. I think the arrangement is strong enough as long as there are large enough backing plates on the inside of the transom. It roughly resembles a low setback jackplate in principle.

peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Fri Sep 02, 2016 4:05 pm

Acseatsri,

It's a manufactured bracket good to 300hp.

See http://continuouswave.com/ubb/Forum3/HTML/021240.html

peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Tue Sep 06, 2016 4:54 pm

Rotten plywood removed from the tank deck cover...
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peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Wed May 31, 2017 10:34 pm

Hi All,

After much delay the tank cover is finally repaired/improved. After days of cutting, sanding and grinding I turned over the thin fiberglass top to the boatyard to finish.

They used three sections of a glass/balsa sandwiched laminate and glassed it to the thin original decking.

My impressions are that it looks perfect, is much lighter, and much stiffer than the original. (I have not seen the bill yet)...

Hats off to the SF Boatworks for quality workmanship. Next step is to cover my new tank.
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jimh
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Re: 1985 Challenger 25 Makeover (continued)

Postby jimh » Sat Jun 03, 2017 5:04 pm

I am enjoying the many comments and photographs of this renovation, and I am sure many other readers are, too. Keep the posts and pictures coming. I am looking forward to seeing the end results and the boat on the water.

peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Mon Jun 05, 2017 8:54 pm

Thanks Jim,

Here are some other miscellaneous repairs:

For some reason CPD liked exposing foam on this rigging job. Maybe a deadline for shipping her to Alaska.

In any case two big holes for the fuel lines (using bent copper tubing), they ran in and then back out of the bait well. In addition, lots of holes for the tow bar mounting brackets (I did not get the actual bar).

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They also used white PVC pipe to line the big wire tunnel into the cabin (jagged sawzall cut, silicone calked). For that we installed a pre-made fiberglass tube and glassed it in (i'll add the pictures of that repair later)

peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Mon Jun 05, 2017 8:57 pm

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peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Mon Jun 05, 2017 8:58 pm

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peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Tue Nov 06, 2018 12:31 am

After forever She is launched!!!

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Initial "day-one" test: [4 blade Cyclone, 19 pitch]

70 Gallons on-board
Max Speed 54 WOT @5500
Happy Speed for SF Bay = 26mph @3050 RPM
Non-planing cruise 10mpg @ 1600

I have not done exhaustive testing (upwind/downwind, trim settings, etc) just a ferry ride from SF to Alameda. I did hunt down some choppy seas (between Treasure Is and Point Blunt) to find the most comfortable RPM.

These E-TEC engine just don't stop; set the RPM and they just plow along--I just love it.

Don SSDD
Posts: 155
Joined: Fri Oct 23, 2015 6:58 am
Location: Nova Scotia

Re: 1985 Challenger 25 Makeover (continued)

Postby Don SSDD » Tue Nov 06, 2018 7:23 am

Beautiful boat, wonderful work, congratulations. Don
1986 Outrage 18 with 2001 Honda 130 HP
Former Owner 1991 Guardian 19 with 1994 Evinrude V4 140HP
Former owner 1987 Montauk with 1998 Mercury 90HP
Nova Scotia

frontier
Posts: 128
Joined: Tue Feb 09, 2016 8:26 pm

Re: 1985 Challenger 25 Makeover (continued)

Postby frontier » Tue Nov 06, 2018 8:05 am

AMAZING. Great job.

jimh
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Re: 1985 Challenger 25 Makeover (continued)

Postby jimh » Tue Nov 06, 2018 2:00 pm

Pete--very nice work and very nice of you to follow up with new pictures.

Re the E-TEC engines: my E-TEC runs like a diesel. You set the engine speed, and that is the engine speed. Steady engine RPM no matter what. I love that aspect, particularly when you have to run into some head seas. The engine speed is not hunting up and down.

Enjoy your new boat.

peteinsf
Posts: 63
Joined: Sun Jan 03, 2016 9:04 am

Re: 1985 Challenger 25 Makeover (continued)

Postby peteinsf » Wed Nov 07, 2018 10:48 am

Thanks Jim...

I did have a question, can I retrofit my 2011 e-tecs with electronic shift/throttle?

Pete