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Discussion Starter · #161 ·
Oh ya, right before the kids got here from Texas, the engine stared acting up and I was thinking NO NO NO! We checked everything. It started hard, idled okay but had no power. We were out on the lake and as I pulled away from Greg in his Paterson, he solved the mystery. The 52 year old starboard side exhaust hose inner liner had collapsed inside and closed it off! I bought just one replacement and swapped it out, knowing that I someday hoped to switch to larger ports and hoses.
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Since we had decided to quit going to the lake in late December last year, it was time to pull the engine out so we could change the starter. My stringers are so tall and the engine sits so low, I couldnt get to the starter without lifting the engine. So we pulled it out and I was really glad that the failed starter had not ruined my flywheel. Other than swapping out the starter for a tiny one, all the engine needed was some touchup paint.
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And that is when it all started. Innocent enough at first, but then...
When I swapped out the fiberglass fuel tanks years ago I went thru quite an ordeal learning how to redo them. I did both sides, front to back but not the center isle. It was dirty, so I cleaned it. Then I found where some of the resin was chipping, so I decided to sand it and then polish it real quick. Then I figured I might as well go all the way to the front so I had to pull everything else out of the hull. We kept thinking of other little things we could do while we were at it. Then I started writing it all down. Then we drug out all of the boxes of parts I had accumulated and the thinking was like this: well, since we are here, we might as well do this, and if we are going to do this, we might as well do that too. And so on. Next thing I know, all of the steering was in a junk pile along with all of the wiring in the boat and everything it used to connect. What the hell?
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I love your posts and have enjoyed reading them in the past and the new ones! My love for these boats comes from my Dad as well so I know how you feel about these things and having our families continue with the tradition is as much emotional as it is fun. Sorry to see the troubles you had, but at least you are using the heck out of the old girl, that is awesome, i have two v drives and i am lucky if the each see 5 days of water a year, its a crying shame! That little white box you talked about is called a ballast resistor it takes the 12 volts coming from your battery thru the ignition and drops it down to 8 or 9 (i think) before it hits the coil and your points, if its not there you would smoke some distributor parts, newer ignitions do not use them as they need full voltage.

What came apart on the engine? I twisted up a motor a few years ago in my Spectra, trashed almost everything, we tracked it down to water filling up the block thru my logs, You sure did a number yours as well...
 

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Discussion Starter · #163 ·
I love your posts and have enjoyed reading them in the past and the new ones! My love for these boats comes from my Dad as well so I know how you feel about these things and having our families continue with the tradition is as much emotional as it is fun. Sorry to see the troubles you had, but at least you are using the heck out of the old girl, that is awesome, i have two v drives and i am lucky if the each see 5 days of water a year, its a crying shame! That little white box you talked about is called a ballast resistor it takes the 12 volts coming from your battery thru the ignition and drops it down to 8 or 9 (i think) before it hits the coil and your points, if its not there you would smoke some distributor parts, newer ignitions do not use them as they need full voltage.

What came apart on the engine? I twisted up a motor a few years ago in my Spectra, trashed almost everything, we tracked it down to water filling up the block thru my logs, You sure did a number yours as well...
Hey thanks!
Re that little white ballast resistor: we took it in and got the "same" part several times but when we tested them, none worked. The "experts: couldnt explain it. Mine was so old that I wanted a backup on hand and when I couldnt get one, I gave in.

I picked up the hot rod engine cheap, figuring the parts were worth it but I had video of it on a run stand so when we got bored, we put it in. I didnt run it hard, never above 4500 and when it popped I had just cracked the throttle a bit more at about 2000. When I took it apart, it was obvious that a stock rod failed but I also found 2 more rods with finger tight rod cap bolts. I shouldnt have run it without having it torn down and checked but I didnt have the cash for that. I ended up trading all the good surviving parts and came out okay. Learning stuff later, those stock rods should have never been in there in the first place, the way that thing was built.
 

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Discussion Starter · #164 ·
Using it with the next two generations... (these are
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mostly last year)
 

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Discussion Starter · #166 ·
more.. trying to get my fat ass up skiing, swimming in late November
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Discussion Starter · #167 ·
The logic sorta flowed like this: the engine has to come out to change the starter, so, that revealed the floor beneath the engine for the first time in 52 years where I could see chipping and peeling old resin on the floors that wouldnt just clean up, so, need to sand the floor, which, really needed sanding all the way up under the deck, so, everything else had to come out of the center isle. You may remember before that I was complaining about how loud my Casale was and all the things that I tried to do to quiet it down. Well, the only thing that worked was blocking off everything under the deck because it was acting like a giant boom box with the vibration that traveled under there along the giant stringer, so, I need a bulkhead up under there. Since Im putting a bulkhead, now I can change the whole steering system and mount the new steering parts to the bulkhead, which, takes us back to the rear of the boat where I pulled out the old steering parts and the tiller and revealed the top of the rudder and the make-shift rudder box. To make room to do all of the steering, I might as well pull off the old 2-7/8" exhaust hoses. I have a set of 3-1/2" teardrop exhaust ports that Smitty Weeks had made for his old Belmont wood boats that Ive been wanting to put on to better match the bigger exhaust logs I just put on with the rebuilt engine. I also have all the parts I need to put a vintage cav plate system on, to make things more versatile, so, I figured I better do that with the exhaust ports to ensure I have clearance for both. Logical, right?

Then Peter shows up and pointed out several other things that should get done while we are at it. Next thing I know, all of Dad's wiring is cut up in little pieces on the floor. No worries, he says it will only take 10 minutes to redo it. Then he reminds me that he doesnt like how far up under the deck my legs are and he says I sit so high it is like riding on a surfboard so he wants to cut the stringers down and move everything back. While we are at it, we can fill all of the stringer holes and re-glass the stringers. Huh?
WTF?

I kept hearing Dad in my head: If it aint broke, dont fix it. Well, to be honest, I've always wanted a bit more of a hot rod since we dont have the kids here much and we dont ski that much and Greg and Jeff are always driving circles around me. Ya know? So maybe all of this makes sense.

Im told that the look on my face was priceless when Peter showed up with the skill saw. After the shock of that, everything else was a piece of cake.

This is what we started with (except the carbs :
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I dont know why, but Al and Greg show up every day about 9 and we work thru till about 4 most days. Their help was priceless. Even in the heat.
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With all of this new(er) stuff, good time to replace the rest of the hardware Dad used 52 years ago.
See the wedged hardwood pieces sitting on the of the grinder below? Dad had those mounted to the top of the stringers to raise and tilt the seats.

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Discussion Starter · #168 · (Edited)
Holy Crap! You are going to what?
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Then on to sanding, grinding, more sanding, drill out the stringer holes, cut dowels, resin the dowels into the holes, more grinding and sanding...
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Discussion Starter · #169 ·
Not a bad fit for a rookie

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Glass, more glass
Note my hatch door handle

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Discussion Starter · #170 ·
More glass, sanding, grinding etc

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Discussion Starter · #171 ·
While we are at it:

(Thanks Gary, Peter and Al)

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Discussion Starter · #172 ·
Remember my vdrive noise complaint? I figure this will assist the bulkhead in killing the sound. I FILLED it with these. That alone dampened the noise from tapping on the deck so my hope is that it will absorb whatever vibration I still get from the shorter stringers behind the new bulkhead. (Hint: It worked!)

And now we start to drill new holes in my freshly repaired stringers. That was tough for me to do for a while but it got easier as I went along. I tried to drill as few as possible.

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Awesome JT, keep the pics coming, I am so glad you are putting your heart and soul in to this, I don't post much but I still check everyday :)
 

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Discussion Starter · #174 ·
Moving the seats was something I had never thought of doing. Getting started with the stringers, I knew it was going to cause me problems with the seats and I cant afford to have them rebuilt. I just hoped that it would work out. Maybe not as good as before, but good enough. I really want to keep things basically how Dad built it and vintage 60's, so I try where I can. My original engine never pushed the boat above 59mph before and it did that comfortably with my fixed cav plates. The engine was tired and after the rebuild and some plate adjustments I picked up a little speed. I understand the concern about not having your legs up under the deck. Maybe not so much on a pure 59mph ski boat but maybe more so on a little bit faster hot rod ski boat. Looking to the future, I went along with this whole cutting the stringers and moving the seats back deal. We actually moved my seat about 6 inches back and at least 4 inches down. Moving the seat-back center section required narrowing the seat-back a bit to get it to fit. My seat is still comfortable but the grandkids arent going to like their middle seat much anymore. It will have to do for now. Maybe next year.

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Discussion Starter · #175 ·
On to the steering:
The original rudder was pretty thin and it turns out it had a slight bend in it, probably from hitting the underwater parking lot.
Got a new bitchin heavy duty rudder from Lance Stump at Custom Fabricated Metals - great guy, big help, nice work
Ill be going back to him for a new steel strut soon
I didnt like the rudder box I had so I replaced it with a new D21
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Discussion Starter · #176 ·
My old SteerMaster helm and the new one Peter made to adapt to a new post
Thanks to RCL and whomever else in Idaho helped me out with the steering parts!
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Discussion Starter · #177 · (Edited)
I have never driven any other flatbottoms besides Greg's. He has a cavitation plate adjustment handle. I didnt mess with it. I also had never adjusted my fixed plates till late last year at Greg's urging. It sped things up but it also porpoised at the top end, which was new to me. Years ago I found an old hex cavitation rod, then the hardware and a Stellings cav handle with an over-ride pedal. I had no understanding how it worked in the water so I just hoped it was going to be a good thing. It is.

Before taking the plates off, I saw that the leading edge wasnt flush with the bottom of the boat. It was bedded into a recess but it stuck down slightly. Apparently this isnt great. When I removed them, I found that the associated 52 year old, non-stainless mounting hardware was indeed rusty and in need of replacing. After polishing the plates up a bit, I messed with shimming them so that they lay flush with the bottom along the leading edge. Then we re-bedded them into the recess, with the shims. At rest, they sit flush and neutral.

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Polishing sucks, patina rules

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Hex cav plate hardware - I COULD USE A COUPLE OF THESE BUSHINGS IF ANYONE HAS THEM - THANKS
They are hex cut on the inside

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Discussion Starter · #178 ·
Got it all lined up and clearing the new exhaust ports

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Made a piece to strengthen the transom and cover the original cav turnbuckle mounting holes
Thought black was a better contrast with the silver flake, just to break it up
We got the sheet, drilled all the holes and cut away for the exhaust ports and then Peter milled it to what it is - Thanks!

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My buddy Hot Rod Bob who lived around the corner and constantly loaned me tools and gave free advice, sadly passed a few months ago. To my surprise, he left me a bunch of his tools including the 12" disk sander and a 14" band saw that we used to cut and clean up all the plates, brackets, mounts, etc - Thanks Bob!

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Discussion Starter · #179 · (Edited)
Re-rigging:
Sorry to see this crack in my bell housing cover - Had a spare

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Finally got to put on some sort of strut brace. Originally it was just 6 small bolts with regular washers and a locknut. The engine sat so low that you couldnt fit a finger between the bolts and the pan. The engine sits a bit higher now and clears it. We did one for the turn fins too.

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Had to cut down the vdrive mounting brackets to match the lower stringers

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Discussion Starter · #180 ·
Decided to mount the engine on rails instead of the old mounts - long story, best option

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