I did some fiberglass and filling to the cap just to do some mindless work. I also started cutting some holes for the hardware. I also treated myself to a new hot glue gun and its bad ass!
made a template for the acorn pop up bow light , I took some measurements and pulled a string for the center.

http://i113.photobucket.com/albums/n...ky0707/076.jpg

http://i113.photobucket.com/albums/n...ky0707/077.jpg

http://i113.photobucket.com/albums/n...0707/080-1.jpg

http://i113.photobucket.com/albums/n...0707/079-1.jpg

http://i113.photobucket.com/albums/n...0707/078-1.jpg



http://i113.photobucket.com/albums/n...ky0707/081.jpg

I cut the the hole for the bow cleat also

I had to make a template for the sending unit pie plate.

http://i113.photobucket.com/albums/n...ky0707/099.jpg


I got my potter putty after 2 weeks and I think the air mail dropped it out of the plane into my front yard.

http://i113.photobucket.com/albums/n...ky0707/073.jpg

http://i113.photobucket.com/albums/n...ky0707/072.jpg

I got lots of hardware in, I had the tank built by SP tanks in Barnegat. they built the last one and it was done right. The new one I had built out of 1/4" plate and it is heavy. It will be a 50 year tank! I also got the hose clamps, neoprene, hose and marine adhesive for the neoprene.

http://i113.photobucket.com/albums/n...ky0707/120.jpg

did some measurements and cut the hole for the gas fill and vent through the for.

http://i113.photobucket.com/albums/n...ky0707/121.jpg


I had Fabtech in Daytona build me the leaning post just the way I wanted it and Ed killed it. I made it in the miniature version of a bigger one. storage under the seat , 3 rod holders and removable back rest

http://i113.photobucket.com/albums/n...707/photo2.jpg

http://i113.photobucket.com/albums/n...707/photo1.jpg

I also had a pile of stainless hardware get delivered from GEM

http://i113.photobucket.com/albums/n...ky0707/122.jpg




and this steering wheel that will go with the boat if I ever sell it !!

http://i113.photobucket.com/albums/n...ky0707/123.jpg

I'm due for a new glue gun..... Thanks!

1. I wish that we had the quality of bass that you guys get.

2. That boat is going to be Bad A$$

strick

Strick its all the nuclear waste that make them big! fishing has been good and getting better.


I had a few hours and an extra set of hands this afternoon to help me get the deck out of the boat.

I have some work to do under the decks before the they go in permanently.

I installed the neoprene strips on the the beds for the tank, and started installing some sleeves for rigging. I cut the holes 1/4" bigger and fill around them with dynaglass thru a caulk tube. I cut the pvc a little bigger and then grind them flush with the hole.

http://i113.photobucket.com/albums/n...707/006-10.jpg

the gas tank grew by a half inch somewhere along the way and it is infront of the rigging tubes by a 1/2" its alright I am just gonna cut pvc to fit through the bulkhead and then deal with rigging

http://i113.photobucket.com/albums/n...707/007-12.jpg

http://i113.photobucket.com/albums/n...707/005-10.jpg



I couldn't deal with the stupid 2x4 going down through the center of the floor box so out it came, I cut a piece of 1" foam that I bonded in there and I am going layup a couple layers of mat and roving to smooth it out for gelcoat. the foam is 1.5" w and 2" tall to create a hard right angle for strength. the front floor box and the bilge will be white gelcoat.

http://i113.photobucket.com/albums/n...0707/009-7.jpg

http://i113.photobucket.com/albums/n...707/011-10.jpg



and strick this one is for you. 51 pounds

http://i113.photobucket.com/albums/n..._5039034_n.jpg

alrighty finally ready to set the deck down inside and prep for bonding. I got the bilge all faired out and somewhat smooth, I installed a backing plate/ pad for the livewell pick up. I had to add another hole for the hoses to go places. I got the front fish box all glassed down and sanded with 60 grit.


http://i113.photobucket.com/albums/n...707/007-13.jpg

http://i113.photobucket.com/albums/n...0707/008-9.jpg

http://i113.photobucket.com/albums/n...0707/012-9.jpg


After everything was sanded down and vacuumed the wiped with acetone, It got a coat of no wax gelcoat. I let it dry overnight then we layed down a coat of gelcoat with with wax. I did this with the little rollers with a velvet roller.

http://i113.photobucket.com/albums/n...0707/017-6.jpg

http://i113.photobucket.com/albums/n...0707/023-2.jpg



next order of business was securing the gas tank forever! I redrilled the holes because I had some choice 1/2"x 6" bolts. So I cut some backing plates out of some 1/4" scrap fiberglass. I coated the bolts in some tuff gell with the touched the tank and bolted everything into place.

http://i113.photobucket.com/albums/n...0707/019-7.jpg


I only have 1/4" clearance front and back which I think is a little on the tight side but it will be fine. plus the tank is 1/4" thick!

http://i113.photobucket.com/albums/n...0707/021-3.jpg


I used the expensive hose clamps for the fill and vent. in apposing directions

http://i113.photobucket.com/albums/n...0707/020-5.jpg


I know I know the grounding wire isn't heat shrinked... I just saw that myself

I finally got all the hardware to assemble the bilge. you don't realize how much hardware it takes to install all this crap!

I got some of the stuff roughed in before I gelcoated so if I made a mistake it wouldn't be hard to fix. The first thing I do is install pumps, fuel filter, thru hulls. then its time to run the wires and hoses. you can see the thru hull transducer( compliments of trayder) also I used the Yamaha stainless fuel filter housing to keep it from getting crappy.

http://i113.photobucket.com/albums/n...0707/025-1.jpg

http://i113.photobucket.com/albums/n...0707/028-3.jpg

then came in some more hoses for the livewell and wash down its start to get busy

http://i113.photobucket.com/albums/n...0707/030-2.jpg

I also installed a brass sleeve back through the bilge drain. I set it in 5200 and sealed it up on the outside. so with it glassed and sealed with 5200 it should last a long time. plus it gives it a clean look.

http://i113.photobucket.com/albums/n...0707/026-2.jpg


gonna get the deck set back in this week

I like to keep my workers moving till the end of the day, so I had to put the deck back in to make some measurement of rigging holes. I had them help me put the top cap back on so I could get a feel of what it was like. and I like it. the flush deck is the cats meow.



http://i113.photobucket.com/albums/n...0707/019-8.jpg


http://i113.photobucket.com/albums/n...0707/018-7.jpg


http://i113.photobucket.com/albums/n...0707/017-7.jpg

http://i113.photobucket.com/albums/n...707/014-10.jpg


http://i113.photobucket.com/albums/n...0707/021-4.jpg


http://i113.photobucket.com/albums/n...0707/024-1.jpg

http://i113.photobucket.com/albums/n...0707/022-3.jpg


here is the shot from inside the floor box, the deck is sitting solid on the stringers.

http://i113.photobucket.com/albums/n...0707/023-3.jpg


shot of the bilge

http://i113.photobucket.com/albums/n...0707/016-8.jpg



I told her she had to help me sand the boat.

http://i113.photobucket.com/albums/n...0707/097-2.jpg

Looks awesome. Love that flat deck.

BA17 thank you I am really excited now that I see it in the boat. the cap fits really well with the flush deck , I tried to take a pic up in the bow of the toe to knee angle of where the hull hits your toes and where your knees are positioned but it doesn't look right in the pic. It is not bad at all and I think its well worth it.

I got the leaning post and Ed did a great job with it from Fabtech marine.

I got the template built for the forward bulkhead and I had a lot of problems getting a straight measurement because of the curvature and angle of the hull . there was a lot of head scratching. I finally got where it looks even with the top cap and the sides. gonna pull it out and transfer the template to one of the panels I layed up .

http://i113.photobucket.com/albums/n...0707/032-1.jpg


once I got the console in the boat with the deck I didn't like the engine box on the front of the console it was to high for me. Plus it was a nightmare trying to figure out how to make a mold for the well because the top was tapered in 3 different ways. I can now flatten the top and make a well with a flange on top to seal it. also I plan to make it into a seat.

http://i113.photobucket.com/albums/n...0707/030-3.jpg

http://i113.photobucket.com/albums/n...0707/031-3.jpg

I chopped 6" off the top of the old engine box and now looks much better.
the livewell will be around 50 gallons.
still have to cut the flange off were the hatch opened and and I might cut 2" out of the width and have the front taper in.


I forgot what shape and size rub rail fits on the 20 the nicest, I am debating on which steering system to use. I used baystar on the last boat, but was thinking of upgrading to a seastar system any thoughts?

got the plug built for the live well, I used 3/4 MDF and a 8" sonnet tube. I ripped the sonnet tube into 4 even pieces( as even as I could get them.) after I got all my measurements on the MDF and cut . I shaved 3/16" off the edges that the sonnet tube was gonna get stapled to, to make it flush with the MDF. After I got the 4 sides and corners all stapled together I cut the top big and used a flush router bit to run it around the outside to make it a perfect top.

once I got that nailed to the rest, I got a 3/4" round over bit to make the rounded edge. .

http://i113.photobucket.com/albums/n...0707/013-6.jpg

http://i113.photobucket.com/albums/n...707/014-11.jpg

http://i113.photobucket.com/albums/n...0707/015-8.jpg


after I got it nailed together It was time to do a little tooling on it to smooth it out. I got some evercoat glaze from the autobody place and started with all the staple holes.

http://i113.photobucket.com/albums/n...0707/016-9.jpg

http://i113.photobucket.com/albums/n...0707/017-8.jpg


I also put a block to extend the rear drain lower
http://i113.photobucket.com/albums/n...0707/018-8.jpg

it took about 3 hours or fairing and sanding to smooth out all the inperfections.

http://i113.photobucket.com/albums/n...0707/024-2.jpg

after I got it smooth and sanded I put some radius wax around the block and some larger radius wax around between the table and the mold

once that was set I waxed it with 3 coats and sprayed 2 coats of PVA.

http://i113.photobucket.com/albums/n...0707/026-3.jpg



I let it dry and it was time to spray it with Gelcoat. I mixed 2 quarts of Gelcoat together with the dark blue tint. I made extra gelcat to store because I would never be able to match it.

I shot the gelcoat with the cup gun.

http://i113.photobucket.com/albums/n...0707/034-1.jpg

http://i113.photobucket.com/albums/n...0707/035-1.jpg


gonna glass it tomorrow.

Sweet!!

Taco marine part # v21-9613 rigid vinyl. Go with the higher end Seastar. Like how you incorporated the concrete tubes in the mold. First class as always!!!! Keep up the great work.

strick

Really impressed with your workmanship! Everything fitting like a glove and neatly rigged. :)

I layed up another mat and 1 layer of 1708 on it and let it set up over night .


http://i113.photobucket.com/albums/n...707/005-11.jpg

I Popped it off the mold and it was relatively easy

http://i113.photobucket.com/albums/n...707/014-12.jpg

http://i113.photobucket.com/albums/n...0707/015-9.jpg

this is where it got tricky I set the circular saw to just under 3/4" and made some rips. I then got in with the flat bar and chiseled away without damaging any gelcoat. once I got a small area of gelcoat opened it went easy, One plastic wedge under and it popped right up

http://i113.photobucket.com/albums/n...0707/017-9.jpg

http://i113.photobucket.com/albums/n...0707/018-9.jpg

http://i113.photobucket.com/albums/n...0707/019-9.jpg

I cleaned it up with the air nozzle then took it outside for a wash and cleaning. I then took my air trimmer and cut all the excess off. I dropped it in the front part of the console and it fits pretty good. I little more trimming and I will be glassing it into place.

http://i113.photobucket.com/albums/n...0707/035-2.jpg

http://i113.photobucket.com/albums/n...0707/036-1.jpg

http://i113.photobucket.com/albums/n...ky0707/037.jpg

http://i113.photobucket.com/albums/n...ky0707/041.jpg


I got the template out for the forward bulkhead and cut it out of the of the 1/2" panel I layed up and it fits pretty tight. might have to do a little trimming to get it back a little bit.

http://i113.photobucket.com/albums/n...ky0707/042.jpg

I decided to put an anchor locker door in so I made a mold for the door and the acess panel at the same time. it was easier to cut the template for the flange and make it 1/8" bigger with some luan.

I also made a box for to go over the fill and vent hose. I will drill 2 holes through it for them and mount it down to the floor to keep stuff from falling on top of the tank.

http://i113.photobucket.com/albums/n...0707/030-4.jpg

http://i113.photobucket.com/albums/n...0707/031-4.jpg

http://i113.photobucket.com/albums/n...0707/033-1.jpg

http://i113.photobucket.com/albums/n...0707/034-2.jpg

http://i113.photobucket.com/albums/n...ky0707/052.jpg

gonna do one more layer of glass on the anchor hatch then pop it off.



I cleaned up the transom with the flush cut bit in the router, I then took out the grinder and cleaned the transom down for some glass I hand sanded the corners and put a radius on the corners to make the glass roll easier.

http://i113.photobucket.com/albums/n...ky0707/050.jpg

coming along great man...

This joke will never get old!!!! AHHHAHAHAHAA

Progress has slowwed with summer time work and fishing. Gonna go at it hard i a couple weeks. It is also giving me time to clean the garage and get more parts in that i need. Anyone interested in spliting a barrel of poly resin? You would have to come to my house to pick up. I only have 5 gallons left and i figure i need 25-30 more. Pm me if you are serious and i can tell you prices

Would be glad to split that poly with u but im in fl :(. I am redoing a 20 and have been following ur thread getting some good ideas from u too! I plan on putting a hermco bracket with a 4stroke on it and having a 25gal transom livewell and was wondering how far forward to put my tank to try and offset some of the weight that I am adding to the stern. If you have any insight it would be great!

I am ready for one myself and would split it but it would be hard for me to make it up there. If there is anybody up here on the board that makes trips from u to nc/VA let me know and I would be glad to compensate the driver

NoBones, I know this is an old post, but do you have a thread on this Hewes resto? Such a cool little boat - I hope to get into one at some point, would love to see your resto process on it.

Thanks,
Mike

Just came across this. Amazing work you are doing, can't wait to see the finished project.

Sweet your ideas are all good

Just curious, Would you have had enough room for a conch style Free flowing livewell where the bilge is, and have just a small bilge forward?

Love the way you salvaged the old VDH insignia of the engine box and incorporated it to the live well, super custom touch. Coring looks awesome.

Not sure you can offset that much weight that far back. That`s a lotta that for a 20.

Not sure you can offset that much weight that far back. That`s a lotta that for a 20.

Very well thought out and great work BTK.

I agree that would be a lot of weight even with the flotation bracket. these boat are very sensitive the the weight distribution.


lord I really haven't decided on colors. I think the inside is gonna be matterhorn white along with the gunnel cap. hull could go a couple different colors. I might do a wisper grey, or the teal color albury boats uses. Or I might just make it mattterhorn white.

thanks bud, I like to see things get recycled so it felt right! after this many years I better be good at doing coring or I better call it quits!

This is gonna be so cool. I'd love to have this setup. Especially if you could do a freeflow livewell.

The quality of this build, I'd trash those Rule Bilge pumps, and get Ultra switches. I've have 2 of those 2-in-1 pump switches fail. 1 wouldn't shut off, one wouldn't fire. Same thing with the rule externals

Remember the good 'ol days, before Rule pumps were "Made in China" or "Assembled in Mexico" they were the best by far and away!!! Now hit's hit and miss junk....mostly miss! :(

I got a couple of Whales. 1300 per since my rules no longer rule and am tired of those damn switches. Picked up some switches similar in design to the ultras. 3 yr warranty on the whales. You can opt for xtended warranty thru Watson Warranty Gp. But only if doing research...

Nice it's all worth it in the end

Ready to start working agian. The weather broke and is now in the 60s. Updates will be posted by the end of the week

class is back in session!

ok so pick up to where I left off.

It was time to get the deck secured to the stringers, I first had to measure and drill the 2 rigging holes, livewell holes and any other adjustments that had to be made. I almost lost my arm when my finger got caught the trigger of the drill with the 4.5" hole saw going!

then it was time to figure out how to go about getting the deck in place in a timely fashion with the rigging coming up through it and not in a panic . remember its all about preparation!

got the chain hoist up to the ceiling and did test on where center would be to lift the deck. I threw some straps through the holes and it went up on a little and with the ass end sagging. so I hoisted it up and just got another little rope through the bilge to the ceiling to level it off.


after it was up I put 2 ropes under the deck and back to ceiling for safety.

so then I put some more ropes up to pull the hoses through the deck so I wouldn't have to deal with them.

once the deck was up I had to get the hoses through the stringer to the center. I cut the stringer and fit the hoses then pulled them out of the way made the cut and glassed the open stringer to seal it up.

I also sliced two pieces of hose to use has chafe protection through the stringer.

Well I wasn't dumb enough to try to set the deck myself so I had a friend help this morning for an hour. I decided to use arjay technologies general bonding putty (potter putty)

http://www.arjaytech.com/index.php/o...-multi-purpose


I knew I had 30 minutes work time with it, which sounds like plenty of time until something goes wrong.

fortunately everything went smooth. We mixed 8 ml mekp to a quart of putty. we mixed about 2.5 gallons of putty in a empty 5 gallon bucket and used a spackel mixer, we ended up using about 2.3 gallons of putty.

I decided to try the mason grout bags and they worked great , we cut the hole to a 1" diameter to squirt the stringers. we used 3 bags, I zip tied the bags shut after filling so you could really squeeze the crap out of them.

I also rounded up 14 5gallon buckets and filled them up the night before


I also did a test sample the night before and cures just like the stuff that was made 40 years ago!!!


the deck went down without any problems, it was good to have an extra set of hands there to put it in place.

Very nice!!! I used the Arjay product for my transom and was very happy with the results, looks like the "putty" also works as advertised!! Looking good!