1991 MONTAUK Renovation: I'm finally ready to dive in!

[scott3294]

Hi All. I have been around the board for a few years. I purchased a 1991 Montauk about two years ago, and, after several flirtations with the idea of renovating it, I have decided to start down that road. I am not a professional handyman or boat expert, but I enjoy working on projects once in a while and I don't mind following directions. This will, by far, be my most ambitious project, short of raising my kids as a single parent! That said, don't be surprised if you see this boat show up on the Marketplace at some point :-)

Here's a set of pics showing what I am starting with. I counted 116 screw holes to fill--seriously, 116!

--Scott

http://s1260.photobucket.com/user/scott3294/slideshow/1991%20Montauk%20Refurb

[jimh]

Wow--someone must have wanted to install a lot of added gear on that hull. It is always amazing how rapidly a few extra holes accumulate. Fixing the holes won't be much of a problem, but you will need to become an expert at color matching gel coat and smoothing and fairing new gel coat patches into the original.

Start your hole repair in the least conspicuous areas. You will learn as you go. When you have mastered the repair and gel coat matching, then fix the holes in the most prominent locations.

Adjust your expectations: if you want to end up with a hull that looks like it just came out of the factory, that may not be practical unless you really become a gel coat repair magician. If you want to have a well-repaired hull with perhaps a few cosmetic flaws here and there, that is entirely possible.

On the bright side, it looks like you got about $50 worth of stainless steel fasteners and dress washers in the deal.

[scott3294]

I shot a video walk around of the boat to give a little more "real world" feel to what I have in front of me. I am pretty sure that due to all the holes that must be filled, I will end of up painting the boat. I just am not optimistic that I have the patience to gel coat the whole boat. We'll see...I am a long way off from that point.
Scott
https://youtu.be/reH1pG58WVw

[scott3294]

Thanks Jim! Your comments are always welcome!! My plan now is to sand and paint...rather than gelcoat. We'll see how I progress!!
Thanks
Scott

[jimh]

If the hull exterior is not too badly damaged, you should try to preserve the original gel coat finish. Boats that have been painted over lose value.

Painting the interior may also be a problem. You will need very durable paint that won't be easily worn away by foot traffic. Before you give up on gel coat repair, you should at least try it out on a few holes to assess the outcome.

To repaint a 1991 hull would be a shame.

[scott3294]

Finally hit my first significant hurdle. Began filling screw holes over the weekend and ran across a decent area of delamination. I cut away the glass and fortunately it was not too terrible, but it will require new wood and glass. It was the first delam find...may not be the last! :-)
Take a look at the photos for more details.
Scott

http://s1260.photobucket.com/user/scott3294/library/1991%20Montauk%20Refurb/Delam%201

[scott3294]

Latest on the refurb. Last of the interior screw holes have been epoxied. See attached picture! Next step is to tackle replacing the area I cut out due to delam.
Also, continue to have good luck on the search for water in the hull. I took a 1 inch spade drill bit to the bottom of the hull about 6 inches from the transom...pristine foam...not hint of moisture. I know its not definitive for the whole hull, but every time I check an area for moisture, I have had encouraging results.
Scott
[img][IMG]http://i1260.photobucket.com/albums/ii579/scott3294/1991%20Montauk%20Refurb/Crazy%20Screw%20Holes/20160730_200000_zps1c3evqiy.jpg[/img][/img]

[Wweez]

You may know the solution in your case,
but most of the time gel coat will not cure over epoxy.
Not in all cases, just most of the time.

Good Luck in your great project!

[jimh]

WEEZ opines:

most of the time gel coat will not cure over epoxy

Not true, and a commonly told old tale. Gel coat cures over epoxy with proper preparation of the surface.

[scott3294]

Here's the latest on the renovation. Finally got around to repairing the area of delamination. First time for everything, right?
Here's the latest video.
Scott
https://youtu.be/ZqhzmhmW7l8

[Trojo]

Good luck, I see we are going through some of the same stages. Interesting video. Thx for posting.