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Discussion Starter · #1 ·
Well here we go....All dress up in a Haz-Mat full body suit and 3M Full Face Respirator....What a mess and lots of issues found during the tear out.

First, there was definitely water rotted ply:


Second, noticed that the plywood was not even bonded to the top cap section of the fiberglass transom:



Third, the plywood that was there had a gap (no bond) between the fiberglass and the ply as seen here where the silicone got between the fiberglass and plywood gap.



Very disappointed in the build of this boat, must have been a Friday or Holiday weekend build. The gap (no bond) allowed the hull to flex in that area there by opening up the seal in the split line between the cap & hull allowing water in.

Gotta start hitting it with a grinder next to smooth it all out for the new "COOSA BOARD" replacement transom, updates to follow.
 

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Discussion Starter · #3 · (Edited)
The project continues

I already had bought the Coosa Board months ago, but thanks for the heads up. Always like options when available.

Suited up ready for battle:




Update as to progress made thus far, inside hull completely stripped down to 100% fiberglass:







Template made for new Coosa Board Bluewater 24 Transom:




The new Transom cut and finished hand shaped with a grinder after several in boat fit checks, ready to install next week:



This has been quite an experience and one hell'va nasty job, would I ever do it again..........probably not, specially at my age. I've got aches and pain where I never thought possible...

Next:
Prep Coosa Board w/resin and glass
Install in the boat
Start step tabbing everything down
Refinish the transom exterior/re-Gel Coat
Finish my rewiring job
Get it wet.........................:))THumbsUp
 

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Nice.... looking good so far. You are on it. I've been watching/waiting for more updates on this one. I like the template you made. Did you hot glue it too or just staples? I've seen granite fabricators use that method several times on my projects and seems to work out real well. Give us more details pleeeze, us wanna be beginners wanna know how too. haha What grit did ya prep with? what are you gonna use for a bedding material, how you gonna clamp in place? what glass you gonna use? You know all the other fun stuff now that your done doin the dirty work. Thanks for posting the update.
 

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Discussion Starter · #6 ·
Nice.... looking good so far. You are on it. I've been watching/waiting for more updates on this one. I like the template you made. Did you hot glue it too or just staples? I've seen granite fabricators use that method several times on my projects and seems to work out real well. Give us more details pleeeze, us wanna be beginners wanna know how too. haha What grit did ya prep with? what are you gonna use for a bedding material, how you gonna clamp in place? what glass you gonna use? You know all the other fun stuff now that your done doin the dirty work. Thanks for posting the update.
Thank you. The template is just strips of 1/8 Hard Board cut down to 2" wide, easy to break off pieces by hand. No hot glue, just staples and handle carefully when done. Please don't consider me anything but a "NEWBEE" as well, this is my first transom job. I've gotten allot of advise from a close friend who's done this before.....maybe that's why it's looking too easy.....:yes:. The cut out of the glass was done with a vibratory saw using a 180 degree blade, cutting like a Tic Tack Toe pattern to remove the glass in smaller pieces. Once glass was removed, used a 40 grit flap wheel to address the wood that wasn't rotten, (wasn't much of that :wink2:), Finish grinding and knocking down the fiberglass lip from the saw cuts I used a 4 1/2"-24 Grit disc, this made short work of the fiberglass lips and edges to provide a nice flat surface when done. Finish work was with a 120 & 80 Grit disc.

Transom material was Coosa Board Bluewater Series 24 @ 2" thick. Transom was prep'd (wetted) using Epoxy Resin and buttered with a layer of Epoxy Resin mixed with Cabosil and chopped strand glass (like peanut butter). Transom was then lifted into the boat and installed with shims that provided the proper spacing and squareness and then glassed in w/3 layers of glass lapping/tabbing onto the hull 6"-4"-2". Clamping was done using screws w/fender washers from the outside of the transom, this allowed adjustment (if needed) to keep the hull and cap properly aligned during cure. There were existing holes in the transom I used and a few new ones I drilled. Once the transom has cured, remove the screws, chamfer all the holes your going to wanna fill with filler (i.e. Marine Tex) allow to cure and sand your brains out, the whole transom that is. Now that's where I'm currently at, sanding the transom. I did install the Knee's last weekend (3/4" AB Marine Ply), pics below. I'll be back in a week or so with further updates.....:partyguy:








 

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Discussion Starter · #7 ·
[email protected]@king [email protected]@d and not to mention that you are never too old to do this type of work considering I am 62 , and still kicking LOL LOL .
I hear ya, at 68 it sure made me think about it allot once I started the project, you know when all the muscles you haven't used in a while start to get real sore and your back is screaming for mercy because you've become a contortionist at the wrong age :hmmm::wink2:........
 
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