1977 Mako 25 Project - AKA Boat Porn

[BFOX76]

I climbed in the boat today after work to spend MORE time digging out wet foam that is still up toward the anchor box and under the forward boxes.

I noticed there was a little water in the hull, but we have not had any rain. It looked to be coming from around the forward bulkhead drain.

Upon further investigation......I cut out a small section of the bulkhead (which I was going to do anyway when I redid the driain lines) I discovered LOTS of rotten foam (BLACK & SMELLY) and water just dammed up @ the bulkhead.

The 2nd picture is looking down between the fishbox and the bulkhead.

So I will be cutting out the box next week in order to remove ALL the wet foam. I would have found it sooner or later. Just another task for me to tackle without spending any $$$$$.

[BFOX76]

2.5 Hours of work this evening got me into a lot MORE WET F'ING FOAM!

I decided to cut out the forward in-floor fishbox first. Just used my cordless recip saw and cut it below the existing deck, then cut it in half. It pulled right out.

Getting the box out exposed the wet foam. Cut the foam out in sections. You can see the large puddle of water. Eventually got all the foam out.

Water was coming through the holes in the front bulkhead. Its like someone forgot to install a drain line. Further investigation in the holes revealed even more wet foam.

So I decided to cut the bottom out of the forward above deck box just before the anchor locker. MOST of the foam in the big pile is just from under the forward above deck box. Very little dry foam extracted.

Got the area cleaned out, but forward of this area (UNDER THE ANCHOR LOCKER) still holds wet foam. Need to dig it out.

I have not fully confirmed that a drain line is connected to the anchor locker drain. Will hopefully be able to figure all this out soon. The good news is that I am getting the boat closer to rebuilding it. Just eliminating all the surprises.

It is still fun!

[J bones]

How much weight do you think you dug out total in wet foam? I would imagine my old girl is carrying an extra few hundred pounds at least in her beautiful moistness!

[BFOX76]

How much weight do you think you dug out total in wet foam? I would imagine my old girl is carrying an extra few hundred pounds at least in her beautiful moistness!

Between the standing water and the water-logged foam, I would say conservatively 350-500 lbs.

[mdfish]

In aerospace production to wet out fiber glass we lay it on a piece of bagging material a few plies at a time, brush on resin, lay another piece of bagging material on top and use the scrappers to work the resin from the center toward the outside. Then you can remove the bagging material and form the plies and cure. Bagging material is like a heavy duty plastic wrap. When laying up plies you should not lay up more than 3 or 4 plies of glass in the same direction in a row. You should alternate plies 0-90 degrees and then 45 degrees. Ideally you should make the layup symmetric. For example 0/0/45/45/0/45/45/0/0 symmetric about the 0 ply in the middle. This is assuming you are using a fabric glass that is woven and a 0 degree ply is the same as a 90 degree ply. Good luck it looks like a great project.

[mdfish]

Oh yeah, if you want a really nice part you can use a pores layer over the glass with a absorbent cloth then the bagging material with a vacuum port and apply a vacuum while curing. This will give you good compaction and get more of the air out.

[BFOX76]

I started tonight by cutting out the floor of the anchor locker to expose and access more wet foam. Used a recip saw, crow bar, dig bar, hammer and my bare hands and got all the easy stuff out as well as some not so easy stuff.

Then I moved on to the bow eye cleat on top of the bow casting platform. It was attached by a support rod to the bow eye where you attach the winch strap. Needless to say it was really corroded. Rusty bolts were no match for the Dewalt Impact wrench. I am not sure what is more fun........this project or playing with all my tools!

Next I noticed some delamination and wet core in the bow casting platform. So I did what any other rehab freak would do and CUT the top skin out to expose all the wet core! Used my cordless circ saw to make a shallow cut and........VOILA! Came right off. I have some grinding to now. I will recore and make good as new.

The #'s of water that I have now taken out of this old boat is probably staggering, but I am so much closer to starting the rebuild. Tonight was a good night!

[wen]

Been following your adventure with great reguard for your efforts.
I have a question/observation about the "IPE" that you are using for a bed material.
Now I have worked with this for decks and ,as you said, it is a rain forrest wood and very resistant to rot,but.....
It's hardness(due to high mineral content) may be a problem in a wet enviornment.I wonder if it might check and split. If so, will that create a problem for you later ?
I know that when you cut the IPE you are supposed to use a wax they sell to recoat the ends to preven checking and splitting.A wax won't do in a marine enviornment and I wonder how well you can soak the grain with resin due to it's very hardness and maybe the resin won't penetrate as well as a softer wood.
I have rebuilt several cockpit soles on old boats and as long as the new lumber was fully soaked in resin,there were never any problems.

Just my thoughts,you're doing a fine job, keep on keepin on !

Wen

[BFOX76]

Been following your adventure with great reguard for your efforts.
I have a question/observation about the "IPE" that you are using for a bed material.
Now I have worked with this for decks and ,as you said, it is a rain forrest wood and very resistant to rot,but.....
It's hardness(due to high mineral content) may be a problem in a wet enviornment.I wonder if it might check and split. If so, will that create a problem for you later ?
I know that when you cut the IPE you are supposed to use a wax they sell to recoat the ends to preven checking and splitting.A wax won't do in a marine enviornment and I wonder how well you can soak the grain with resin due to it's very hardness and maybe the resin won't penetrate as well as a softer wood.
I have rebuilt several cockpit soles on old boats and as long as the new lumber was fully soaked in resin,there were never any problems.

Just my thoughts,you're doing a fine job, keep on keepin on !

Wen

Wen,

You are exactly correct. I have scrapped the IPE idea for bedding my fuel tank. I havent fully figured it out. The one thing that I know I DONT want is FOAM in the fuel tank compartment. I am considering using 3/4" thick PVC board to bed the tank on. I am open to suggestions. I appreciate your thoughts. Thank you.

[mdfish]

Polyurethane bar or HDPE