15 Whaler Super Sport Project

Repair or modification of Boston Whaler boats, their engines, trailers, and gear
dtmackey
Posts: 132
Joined: Thu Sep 28, 2017 9:29 pm

Re: 15 Whaler Super Sport Project

Postby dtmackey » Sun May 06, 2018 10:48 pm

Spraying at my friend's shop didn't work out from a logistics point, so I sprayed outside and ran the lawn irrigation for 15 minutes to help knock down any dust.

All the smooth interior is painted. Non-skid areas may have some paint, but those are getting non-skid and painted a slightly darker so it has a different look.

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I masked over the hull stencil and once removed you can see how close the color match is.

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Shot of the riser added to the rear thwat seat so the 15 gal tank will fit underneath and also position better for sitting.

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Light connection box and stern light hardware.

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The rear section of the rails was a little bent, so I'm ordering new tubing and will bend up to match the old without the damage.

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Installed the new drain tubes.

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Once the non-skid is done I can push forward on the assembly of the interior.

D-

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Dutchman
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Location: Kalamazoo, MI (South Haven)
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Re: 15 Whaler Super Sport Project

Postby Dutchman » Tue May 08, 2018 9:43 am

Looking good
EJO
"Clumsy Cleat"look up what it means
50th edition 2008 Montauk 150, w/60HP Mercury Bigfoot

dtmackey
Posts: 132
Joined: Thu Sep 28, 2017 9:29 pm

Re: 15 Whaler Super Sport Project

Postby dtmackey » Tue May 08, 2018 10:37 pm

More progress tonight.

Bent the new rail to match the damaged rail and installed. Now it looks nice and straight.

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Rubail is installed and also rail.

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On small Whaler type project I've never understood while people insist on poor quality crimp connections that are exposed to the salt air. 3M makes a silicon grease filled one crimp connector that is better than an exposed terminal lug.

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Hopefully non-skid on Sat and then I can install the interior next week and start the rigging. This is the fun part and I may grab the motor from storage in my barn Sun night.

D-

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Dutchman
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Location: Kalamazoo, MI (South Haven)
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Re: 15 Whaler Super Sport Project

Postby Dutchman » Wed May 09, 2018 10:30 am

You're getting close, can't wait to see her out on the water.
EJO
"Clumsy Cleat"look up what it means
50th edition 2008 Montauk 150, w/60HP Mercury Bigfoot

dtmackey
Posts: 132
Joined: Thu Sep 28, 2017 9:29 pm

Re: 15 Whaler Super Sport Project

Postby dtmackey » Thu May 10, 2018 9:56 pm

Paint has been a back and forth struggle for me with this project. Seems like the cost of paint has suppliers not carrying the colors I want or the quality of paint I choose. The distributor of Awlgrip did not carry 3 different shades of slightly darker to offset the color of the non-skid, so I've decided to spray the same color as the entire interior. It's not a big deal, but I like the 2 tone effect.

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The other thing people will notice right away is I've masked for far more non-skid than Whaler every had. This is on purpose as I feel this was a design flaw in the 15' design. There is too much smooth deck than on a wet day not even boat shoes can grip, so I'm increasing the non-skid area. The other concern is this boat will see use as a dingy to a larger boat and we tend to enter and exit the boat from the bow to a swim platform, so grip is a necessity.

Non-skid will go down over the weekend.


Also started the rigging of the console since that will be ready to go in next week when the non-skid is dry. I forgot to install a marine power outlet and LED blue lights under the console for interior night lighting and ordered those today.

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D-

dtmackey
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Re: 15 Whaler Super Sport Project

Postby dtmackey » Sat May 12, 2018 11:43 pm

Good day today. Ran up to the lumber yard and grabbed one more piece if Sipo mahogany to complete the last piece for the rear seat storage and laminated that up. While near the barn, I grabbed the Yamaha 70 a brought it home and will paint the motor next weekend and then it's ready to mount and rig. The motor is currently bolted to the bracket that will attached to the engine stand.

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On the way home I swung by a friend's house and he gave me his Awlgrip flattening again so I could "dumb" down the gloss on the non-skid.

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For those keeping tabs on this project, I did want to offset the non-skid color, but the local Awlgrip supplier did not have any of the 3 color codes I gave them, so I went all the same Whaler Desert Tan and I'm not disappointed. On past projects I've always sprayed and sprinkled the non-skid, follow with 2 - 3 more coats sprayed. This I could not spray due to location and weather, so opted to roll. I rolled the first coat of Awlgrip and then used the saltshaker process with a mix of coarse and fine Griptex. This was followed with 2 more rolled coats of Awlgrip about 45 mins apart. Awlgrip says to use the Awlcat #3 for rolling, but I used Awlcat #2 with flattening agent.

About 20 mins after the last coat I pulled the tape and I'm very pleased with the outcome.

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Interior goes in tomorrow night and rigging starts this week.

D-

dtmackey
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Joined: Thu Sep 28, 2017 9:29 pm

Re: 15 Whaler Super Sport Project

Postby dtmackey » Tue May 15, 2018 11:03 pm

Made more progress tonight after a crazy day in the office and was able to get the steering and controls in and then screwed the interior in place. Everything is now secure and ready for finishing before I can launch.

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More running around to get the small stuff and also finish off the wood. Hope to start on the motor this weekend and have it all painted and ready to mount early next week.

D-

PatSea
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Re: 15 Whaler Super Sport Project

Postby PatSea » Wed May 16, 2018 6:58 am

Outstanding work. Congratulations!!

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Dutchman
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Location: Kalamazoo, MI (South Haven)
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Re: 15 Whaler Super Sport Project

Postby Dutchman » Fri May 18, 2018 9:32 am

Wow, Wow, & Wow. Can't wait to see the pictures of her in the water.
EJO
"Clumsy Cleat"look up what it means
50th edition 2008 Montauk 150, w/60HP Mercury Bigfoot

dtmackey
Posts: 132
Joined: Thu Sep 28, 2017 9:29 pm

Re: 15 Whaler Super Sport Project

Postby dtmackey » Sat May 19, 2018 11:25 pm

Battery arrived today (Group 22) and IMHO this is the perfect battery for 13 and 15 Whalers. Smaller in size than a group 24 and since it's AGM it can stand deep cycling without the concern of damage of the typcial lead/acid battery.

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Battery will tuck inside the rear compartment once the back panel is installed. I could not fit a group 24 in this space.
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Rigging is slow as I pick and choose how to route things and I've changed my mind on a couple things as I make progress.

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Motor is being prepped for painting and it was easier to remove the transom bracket and prep.
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Found the trim motor was a little corroded and while it still worked, I decided to order a new one.
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In order to keep as much rigging hidden as possible I cut a rigging tube and installed backwards into the wood to route the wires in/out of the rear storage compartment.
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And the steering cable that would normally move and scratch the Awlgrip was secured and does not touch anything but the pads holding it in place.
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This week will be slow since I have to varnish the rear of the storage compartment and also wait on sime UPS deliveries.

D-

dtmackey
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Joined: Thu Sep 28, 2017 9:29 pm

Re: 15 Whaler Super Sport Project

Postby dtmackey » Sun May 20, 2018 10:51 pm

A little more progress.

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dtmackey
Posts: 132
Joined: Thu Sep 28, 2017 9:29 pm

Re: 15 Whaler Super Sport Project

Postby dtmackey » Sun May 20, 2018 11:00 pm

A little more progress.

Battery is mounted.
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With back panel in place.
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Since I could not find a battery tray or box for a group 22 battery, I have to build my own from starboard. Initial thoughts were to place on the deck and strap it, but after thinking about it, I wanted to have something between the non-skid and battery and also provide additional restraint over a simple strap.
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Backside of storage has areas for cables to exit. Now trying to varnish this piece as least once per day. Would really like to install and wrap up this project soon now that the temps are getting nice.
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For the bottom pan of the storage compartment I cut up the original Whaler piece and modified it to fit. This is mocked up and it will stand about 1-2" off the floor. Ideally this compartment will be for life jacket and water ski lines, so no biggie if they get a little wet.
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D-

Don SSDD
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Location: Nova Scotia

Re: 15 Whaler Super Sport Project

Postby Don SSDD » Mon May 21, 2018 4:52 am

Beautiful detailed work and photos, better than when new from the factory. You have a lot of talent.
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

dtmackey
Posts: 132
Joined: Thu Sep 28, 2017 9:29 pm

Re: 15 Whaler Super Sport Project

Postby dtmackey » Mon May 21, 2018 11:16 pm

More progress tonight. Boat is now on the trailer and my son helped me flare the forward locker drain tube. Motor is prepped for paint and only needs a cleaning and wipe down. Trim motor should arrive Wed, so my goal is to have he motor all painted and ready to mount this weekend.

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Boat is on the trailer so I hope I won't be climbing in/out that many more times.

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More parts ready for paint (trim motor to be replaced).

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Etec 75 that I mentioned earlier in the project. Bought it for $400 as a "locked" motor, but the seller did not know it had a bad starter and the motor was fine, so painting and new decals. At first I was going to use on the Whaler, but at 320lbs, its just too heavy.

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Etec cowls, had paint mixed and they botched the color and it's eggplant, not blue and realized this after the first pass on the cowl. So I used the paint to spray a guide code to be sanded and will get the proper color and spray the entire motor this weekend and install the decals.
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D-

dtmackey
Posts: 132
Joined: Thu Sep 28, 2017 9:29 pm

Re: 15 Whaler Super Sport Project

Postby dtmackey » Wed May 23, 2018 10:40 pm

Painted the Yamaha tonight and just in time. After I moved the pieces inside, it started to shower 10 minutes later, so I was happy to have this done to let the paint cure and assemble over the weekend and hopefully mount the motor on the boat.

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Trim motor in this pic is the old one that is being replaced.

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Reflections almost look like paint imperfections, but the lower unit looks fine.

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Hope to mount the motor this weekend.

D-

jimh
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Re: 15 Whaler Super Sport Project

Postby jimh » Thu May 24, 2018 9:18 am

DT--you are a machine--I can't believe the amount of work you can get done. And the work is amazing quality. Great stuff.

I love the great match between the re-paint and the original hull color as seen in the stencil number on the transom.

But the best part: you have taken pictures of all the work. That's even harder to manage when you're the one doing all the work, too. Great article, great, work, great pictures.

dtmackey
Posts: 132
Joined: Thu Sep 28, 2017 9:29 pm

Re: 15 Whaler Super Sport Project

Postby dtmackey » Thu May 24, 2018 10:51 pm

Thanks for the kind words Jim.

Got home from work tonight and assembled the motor and mounted on the boat.

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Rigging started in the now enclosed storage compartment. I still need to clean up some wiring and longer set of battery cables to the motor. Everything exposed to sun will be run in loom to protect and provide a clean look.

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Wiring to the bilge pump is not ideal, but the shortest distance between two points.

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Storage is nice and conceals the tank. Holds 5 life jackets, horn, fire ext and a little more.

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Still more rigging to go.

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Trim motor arrived and it was the wrong one, so I'm ordering another unit tomorrow to arrive sometime next week. By then everything should be done and just waiting on the last thing.

D