1963 13-footer Restoration

Repair or modification of Boston Whaler boats, their engines, trailers, and gear
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opencage
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1963 13-footer Restoration

Postby opencage » Wed Jun 26, 2019 9:37 pm

I bought 1963 Boston Whaler 13-footer with a trailer, and engine.

The trailer seems a little newer but not much .

The engine is a c.1985 Nissan 40-HP two-cylinder two-stroke-power-cycle engine.

I got to take out the boat a few times and was hoping to enjoy it for a season before I restored it. Then I realized that one of the leaf spring hangers broke off the trailer frame and figured I oughta repair the trailer before I moved from Colorado to Michigan.

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Fig. 1. Top: bought condition, bottom: interior and rub rail insert removed
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I stripped the hull bare, winterized the outboard, then disassembled the trailer. I cut off the other hangers and ground off the rust added bolt-on hangers and replaced the double-eye springs with some slippers. Also used Phospho and Rustoleum primer and paint along with new hub assemblies. I was worried, but it made the 1200 mile trip

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Fig. 2. Stored for winter upside down on blocks and covered
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Fig. 3. Began to disassemble the trailer to replace hangers, remove rust and repaint
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Last edited by opencage on Fri Jul 05, 2019 4:12 am, edited 4 times in total.

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Re: 1963 13 Restoration

Postby opencage » Wed Jun 26, 2019 9:38 pm

4a.jpg
Fig. 4 Angle-grinder-ed everything to remove rust, then Phospo-ed, primed, and painted with white flat Rustoleum.
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Fig. 5. Re-assembled with new hardware, bolt-on hangers, and slipper leaf springs
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Fig. 6. Ready to make the trip halfway across the country
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Last edited by opencage on Fri Jul 05, 2019 7:41 pm, edited 3 times in total.

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Re: 1963 13 Restoration

Postby opencage » Wed Jun 26, 2019 9:47 pm

I sold the older Nissan 40HP 2-stroke before we left Colorado. I got the go-ahead from my wife to buy a new motor that "doesn't stink".

I'm staying at my parents' place and they have a pole-barn and I'm now stripping the bottom paint and topside paint that was put on the hull back in the 1980's. I'm having a lot of success with Citri-Strip. But for me, letting it sit over night with plastic on it wasn't as effective as just letting it set an hour or so and then scraping. The gel stayed "wet" and was much easier to scrape and seemed to take off as much paint. When I left it over night with plastic covering it, it still dried quite a bit, was hard to scrape, and I had to reapply the Citri-Strip in many places to be able to scrape.

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Fig. 7. In my dad's pole barn, getting covered in paint stripper
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Fig. 8. The first night after stripping, the transom and aft white sections were just sanded, the rest were stripped with citric-strip
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Fig. 9. Most of the bottom paint is gone
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After finishing stripping, the next steps are epoxying/relaminating some soft spots, some small fiberglass repairs, then fairing. Oh yeah, and I gotta fix that bow eye hole too.

Then on to re-gel coating and likely a Suzuki 30HP 4-stroke, I have a couple of other posts asking about these specifically:

Gelcoat (and sudden gelcoat creases): http://continuouswave.com/forum/viewtopic.php?f=6&t=4324

Repower: http://continuouswave.com/forum/viewtopic.php?f=7&t=4448
Last edited by opencage on Fri Jul 05, 2019 7:52 pm, edited 2 times in total.

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Re: 1963 13-footer Restoration

Postby opencage » Thu Jul 04, 2019 7:59 am

Stripping is basically done. I understand why folks say just pay for soda-blasting. I know it doesn't look like much else got done, but trust me it's better. It was tough getting the paint out of the trough under the lip/rub rail area.

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Fig. 10. Finishing stripping, there was a white topside paint on top of the off-white gelcoat
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Fig. 11. Removing the residue and remaining bluegreen color of the old bottom paint
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Fig. 12. Ready for sanding
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Last edited by opencage on Fri Jul 05, 2019 8:12 pm, edited 2 times in total.

jimh
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Re: 1963 13-footer Restoration

Postby jimh » Thu Jul 04, 2019 8:26 am

Please go back and edit all your posts to provide captions for the 12 illustrations.

You are going to have a lot of sweat-equity in this boat.

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dg22
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Re: 1963 13-footer Restoration

Postby dg22 » Fri Jul 05, 2019 4:35 pm

Great job! From the pics, the bottom looks to be in good condition. My 1967 13-footer had a lot more blistering which I sanded out and then applied 2 coats of Inter-protect, filled the imperfections with Watertite, a 2-part epoxy marine filler, then a few more coats of Inter-protect and then 2 coats of bottom paint. All the best with your project.

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Re: 1963 13-footer Restoration

Postby opencage » Fri Jul 05, 2019 8:19 pm

Jim, added the captions. I agree about the sweat equity: learning a lot; enjoy working with my Dad on a boat my Son will use someday, too.

dg22, thanks. I am very surprised at how good the gelcoat is. There is really almost no blistering. Only three delamination spots that aren't too big and don't concern me (yet). There were some repairs under that bottom paint so still plenty of dremel-ing and epoxy and fiberglass work ahead of me, but nothing that really scares me.

Like anything, it's just hard getting the time.

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Re: 1963 13-footer Restoration

Postby opencage » Sun Sep 29, 2019 9:29 am

I'm still working on this.

Life happens. Found and bought a house, moved again, futzed around with generic new house stuff, started a new job, got the school year started (I'm an elementary school teacher), then finally got the boat up to the new house's garage. The garage is insulated and heated, so I'm looking forward to being able to work on it throughout the winter, the goal is definitely have it done by next season.

IMG_0040.jpg
Fig. 13. Dremel tool used on cracks.
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IMG_0039.jpg
Fig. 14. I used a Dremel tool on gunwale edge that will be under the rub rail; it was good practice.
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Last edited by opencage on Sun Sep 29, 2019 9:38 am, edited 1 time in total.

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Re: 1963 13-footer Restoration

Postby opencage » Sun Sep 29, 2019 9:37 am

In the new garage, ready for more work.

Big things left for the bottom of the hull:
- finish the cracks (dremel, fill ((west 105 + 206)), fair/sand)
- fix three delimitation spots (west 105 + 206) using sand bags for bottom of hull and 1x8's and clamps for hull wall
- fix the bigger "dings" using the west system instructions for minor fiberglass repair
- sand the old gelcoat one more time and re-gelcoat with FGCI's crushable gelcoat

Then flip it over and repeat for the cockpit. I will try to do my best to photo and document as much as possible. I know I'm more confident doing this stuff because others have done that.

IMG_0361.jpg
Fig. 15. Bottom hull at bow.
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IMG_0360.jpg
Fig. 16. Hull
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IMG_0359.jpg
Fig. 17. Port side
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Masbama
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Re: 1963 13-footer Restoration

Postby Masbama » Sun Sep 29, 2019 10:55 am

Looking good.
Question: Does the boat rest entirely on the keel rollers? I see no bunks in the pictures.
If so, that may be the cause of the keel rash seen in the pictures.

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Re: 1963 13-footer Restoration

Postby opencage » Sun Sep 29, 2019 12:40 pm

Masbama wrote:Looking good.
Question: Does the boat rest entirely on the keel rollers? I see no bunks in the pictures.
If so, that may be the cause of the keel rash seen in the pictures.


Thanks! I know it's far from finished but I'm happy with what's done so far.

Here's the finished trailer with bunks. But those are really only for lateral support. I used the trailer article: http://continuouswave.com/whaler/reference/trailering/trailer.html to set it up. From everything I've read and understand, the keel is meant to hold most of the weight.

But I do plan on reinforcing the center keel with some glasswork and making sure the gelcoat there isn't thin (but also not too thick, I have a wet mil gauge for the application), still debating the keelguard or not when finished, I know I'd prefer to not have it. And doing the FGCI gelcoat will let me relatively easily repair and gelcoat dings.

IMG_0282.jpg
Fig. 18. Restored trailer for 1963 13-footer.
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Re: 1963 13-footer Restoration

Postby Masbama » Sun Sep 29, 2019 3:08 pm

Interesting!
Why would the FGCI gelcoat be easier to use and repair as opposed to other brands of gelcoat?

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Re: 1963 13-footer Restoration

Postby opencage » Sun Sep 29, 2019 4:12 pm

Masbama wrote:Interesting!
Why would the FGCI gelcoat be easier to use and repair as opposed to other brands of gelcoat?


Ah, good clarifying question.

I just mean that since the gelcoat will be new and of a generic color from this supplier, it'll be easier to buy and color match, than having to do so with older oxidized gelcoat using Spectrum for example.

Other than that I don't see it being easier other than that it's supposed to flow/even out better (like paint) and require less sanding, per the manufacturer, don't have the experience yet.

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Re: 1963 13-footer Restoration

Postby Bayou Bum » Sun Sep 29, 2019 7:24 pm

Redoing a 13' myself. Are you going to use any primer or undercoat for the brush on gel coat ?
I originally planed to use an epoxy barrier undercoat before using brush on gel coat, but now I'm thinking it's not going to add any real additional protection sitting in between gel coat and gel coat.

Your thoughts?
1963 13' Classic

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Re: 1963 13-footer Restoration

Postby opencage » Sun Sep 29, 2019 8:05 pm

Bayou Bum wrote:Redoing a 13' myself. Are you going to use any primer or undercoat for the brush on gel coat ?
I originally planed to use an epoxy barrier undercoat before using brush on gel coat, but now I'm thinking it's not going to add any real additional protection sitting in between gel coat and gel coat.

Your thoughts?



I asked that question specifically to FGCI. You can see my summary of my conversations here.

In response to that question, the tech said it wasn't necessary to add the epoxy barrier coat. Gelcoat doesn't fail that often. My situation is similar to yours I think in that 99% of the time it's on a trailer, but I might go on vacation somewhere for a week. He said it's just not worth it. Just be sure to follow the preparation procedure very well.

I have their white brushable gelcoat in my basement ready to go, just need to finish up the repairs first.

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Re: 1963 13-footer Restoration

Postby Bayou Bum » Sun Sep 29, 2019 8:21 pm

Got it, Thanks.
Good Luck and post up pics when you're done!
1963 13' Classic

rtk
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Re: 1963 13-footer Restoration

Postby rtk » Wed Oct 02, 2019 7:00 am

Nice work opencage!

Stripping is basically done. I understand why folks say just pay for soda-blasting. I know it doesn't look like much else got done, but trust me it's better. It was tough getting the paint out of the trough under the lip/rub rail area.


I can't agree with you more. After spending countless hours (I still have a long way to go) sanding and grinding my 1971 Outrage 21 project having the entire boat soda blasted would have been the smart choice. After soda blasting finish sanding is still necessary but it goes much easier and quicker. A rough estimate to do my boat was about $1,000. I've probably spent about $300 on sanding supplies/equipment. I had some time on my hands this spring and summer due to a voluntary separation from work so I figured I would just "have at it".

The prep work is not a pleasant activity but it is the most important part of the job. The heated garage is great to have for this type of project. Taking tarps off every time time I go to work on the boat is tedious.

Best of luck with the balance of the project.

Rich

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Re: 1963 13-footer Restoration

Postby opencage » Sun Oct 06, 2019 4:36 pm

rtk wrote:Nice work opencage!

Stripping is basically done. I understand why folks say just pay for soda-blasting. I know it doesn't look like much else got done, but trust me it's better. It was tough getting the paint out of the trough under the lip/rub rail area.


I can't agree with you more. After spending countless hours (I still have a long way to go) sanding and grinding my 1971 Outrage 21 project having the entire boat soda blasted would have been the smart choice. After soda blasting finish sanding is still necessary but it goes much easier and quicker. A rough estimate to do my boat was about $1,000. I've probably spent about $300 on sanding supplies/equipment. I had some time on my hands this spring and summer due to a voluntary separation from work so I figured I would just "have at it".

The prep work is not a pleasant activity but it is the most important part of the job. The heated garage is great to have for this type of project. Taking tarps off every time time I go to work on the boat is tedious.

Best of luck with the balance of the project.

Rich



Yeah, I'm not looking forward to doing the cockpit, but I'm hoping now that I know what I'm doing it'll go a bit faster. And it gives me a good idea of the hull condition and specific spots to hit for sure.

Thanks, I'll keep posting as I keep working. I've been fishing and golfing during my free time while the weather's still decent, but I know if I don't start soon, I might not be done by spring.

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Re: 1963 13-footer Restoration

Postby rtk » Mon Oct 07, 2019 6:48 am

I found that a Dremel Multi-Max with the detail sanding pad and a "mouse" type sander came in very handy in sanding the tight spots.

https://www.dremel.com/en_US/tools/-/su ... ti-purpose

I have a 1973 13' Whaler in the garage also that needs quite a bit of attention. That'll be my winter boredom avoidance project.

Enjoy!

Rich

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Re: 1963 13-footer Restoration

Postby jimh » Mon Oct 07, 2019 8:58 am

I do not see any difference between the work shown in Figs. 10, 11, and 12, and the work shown in Figs. 15, 16, and 17. What is the difference?

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Re: 1963 13-footer Restoration

Postby opencage » Mon Oct 07, 2019 8:20 pm

rtk wrote:I found that a Dremel Multi-Max with the detail sanding pad and a "mouse" type sander came in very handy in sanding the tight spots.

https://www.dremel.com/en_US/tools/-/su ... ti-purpose

I have a 1973 13' Whaler in the garage also that needs quite a bit of attention. That'll be my winter boredom avoidance project.

Enjoy!

Rich


Thanks for the info, I'll check it out. I've been using a Harbor Freight dremel-type for removing the gelcoat cracks and just wet-sanding by hand for any tight spots to make sure I don't do too much.

Good luck on yours!

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Re: 1963 13-footer Restoration

Postby opencage » Mon Oct 07, 2019 9:09 pm

jimh wrote:I do not see any difference between the work shown in Figs. 10, 11, and 12, and the work shown in Figs. 15, 16, and 17. What is the difference?


Ha, yeah, there's not a ton of difference, a little more stripping, sanding, and grinding out of the cracks. And in the new garage.