1986 19 foot Ali’i Kai rebuild

Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
I’m midway through a rebuild of a 1986 19x8 Alii Kai & decided to post my progress. I’ve decided to start this thread because I’ve had a hard time finding too much information about these boats. From what I’ve seen about these older 19 footers, they are a very similar hull to the glasspro 19’s except with chines and a small keel running down the center. The boat I acquired was demo’d down to the bare hull and layed up pretty thick in the center tapering out to the sides. New ply stringers and transom was installed and also layed up with glass. The boat sat like this for a couple of years and this is when I acquired it. Aside from dabbling with surfboards coming into this project I had very little experience with glasswork. Fortunately, I work with a bunch of knowledgeable “boat guys” that are always willing to offer tips or advise.

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Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
The boat also came with this brand new custom aluminum gas tank. 80 gallons, 2’x8’ and baffled. Because the bottom of the tank does not follow the deadrise as it flattens out at the stern I had to raise the current stringers a bit for it to fit under deck properly.

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Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
My first step was to grind everything clean. Being that the boat was sitting for a few years and the transom glass job was left open at the top, I needed to pull all the ply from the transom which was rotting out. The 2 outer stringers were also left open at the top and started to delay a bit. After peeling/grinding the glass off of those stringers. All the wood underneath was still rock solid. I raised the stringers using kaycell and faired using thickened epoxy to get them ready to lay up. I decided to use kaycell and epoxy for everything to hopefully offset my relative inexperience with boat work.

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Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
Installed the gas tank which I epoxy primered for longevity. Put in deck support cross members vs traditional bulkheads that get laminated to the hull. I did this because I heard the original boat did not have any bulkheads to begin with aside from the single one up front, and along with the heavier layup of the hull it should be plenty support. Another consideration was that I wanted my inspection ports in the berth, where they would be subject to minimal amounts of exposure to water. So if I tipped the trailer tongue down, I would be able to see if there was water coming from anywhere under deck. In hindsight, I wished I made true bulkheads and compartmented the airspace.

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Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
Forgot to mention installing a 1000 watt furuno transducer under deck also. Took measurements of where the fuel pickup and transducer is so that if anything happens I can cut and install inspection ports reactively. I’ve been told that if I put them in now, they are likely the first place that will leak through deck. Next step was working on the dash/berth area.

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Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
Built some boxes for the pedestals. Not too much storage but the biggest thing was keeping bolts out of the deck. Bought some shock pedestals and found some original Ali’i Kai seats on Craigslist. Tried to find a sweet spot where sitting and standing would both be fairly comfortable but we’ll see. The only thing I could really get a feel fit was making eye level the same when both sitting and standing.

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Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
Next was a little bit of of cosmetic work. I didn’t like how tall the upper part of this add on ply glass cab, so I decided to change up the front to more of a “radon” look. It also gives me a little compartment up front. I plan on putting a hatch in the center square and using it for anchor line storage.

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Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
Redid the old ply glass roof and replaced with kaycell. Took the boat out of the tent to take a look at the new side profile. Not the best, but a lot better than what it was without tearing off the old cab.

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19 Alii Kai Maui
19 Alii Kai Maui
Sidenote, new trailer is in the works haha. Towing it to my house was a huge roll of the dice but it made it!
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Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
Filled and glassed the grinded out rub rail, then laid on some epoxy fairing compound. Block sanded and cleaned up fillets till my fingers fell off, laid more fairing compound and did it again. I’ve come to the conclusion that I could keep repeating this cycle and still find new imperfections every time.

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Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
Paint was the next thing on the list. My previous job was house painting for many years so I was fairly comfortable using hvlp and conventional paint gun setups. The only problem is my boat is under a temporary tent, next to my house fairly small neighborhood. Because of this I had to commit to buying awlgrip formulated for rolling and tipping. After watching many boatworks today videos and talking to co workers with experience I ended up picking up a bunch of mohair rollers and some expensive Corona brand tipping brushes. On goes the awlgrip finish primer.

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Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
Being that I have never used a brush and roller to apply anything close to this type of material, I decided to practice on my fish box lid. I could take it into the controlled environment of my garage and also practice non skid application at the same time. I ended up going with the med/fine non skid from fiberglass hawaii. This is also where I picked up all of my kaycell, fiberglass, and marine epoxy. I am pretty happy with how it turned out and amazed with how well this material flattens out.

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Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
Decided to go fairly simple with my color scheme. Grey hull with awlgrip off white for cab and deck. Black stripe on the bottom of the cab and black lip on the roofline. Gonna go with the same “teak decking look” non skid pattern that was on the fish box lid for the deck also. Because I worked so much on the fairing I was thinking not webbing anything but it may be too blinding with all that white top side. Not too sure about polishing out the gel coat on the bottom or putting some paint on there. Again while putting down the gray on the hull I was amazed at this paints ability to flatten out. This is 3 coats sanded with 400 grit between coats. Because it was painted out in the elements I sanded between coats to help with any dust or debris that may have got on the wet paint each time. Hopefully I can start on the off white soon. Really depends on the weather where I live. Little 5 minute showers can come along if I’m not careful and ruin the paint.

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Jul 1, 2020
29
68
36
Maui
Name
Cory Palmeira
Boat
19 Alii Kai
Here is a pic of a pair of fuel injected high thrust Yamaha 60’s being prepared to be shipped to me from the Big Island. I also bought brand new Yamaha control cables and oem Yamaha twin binnacle controls. Looking into a sea star hydraulic steering system as well. Also picked up some custom cut safety glass for my windows, and trimlok locking window gasket to hold them in place on the cab.

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acefuture

@acecraftco
Apr 3, 2019
738
734
Costa Mesa, CA
Name
Ace
Boat
Always changing
This thing is nuts! Incredible work. Did you cut relief holes through the bulkheads to allow potential water to make its way to the back? From the photos it doesn’t look like it, but does the boat have a bilge? Might be worth creating one for any water that potentially makes its way below deck.

Awlgrip is really a Bitchin product. I just painted my outrage with the same method. Did you go high build and 545 first? Or any primer for that matter?

I’ll be in Maui in September. Would love to see this bad boy on the water!
 
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19 Alii Kai Maui
19 Alii Kai Maui
Thanks! After fairing I did go with 2-3 coats of awlgrip 545. If you look close the bulkheads are open at the bottom, making for 5 separate air spaces vs 15. I’d also love to see this boat in the water in September, we’ll see!
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Rocket Dog

Tagging and Bagging
  • Mar 2, 2010
    1,444
    605
    SoCal
    Name
    Rocket Dog
    Boat
    passenger again
    wow, this is a killer build. id the boat based on the old Glasplay's from Washington in the states? 19x9 seems that the beam is a foot wider.
     
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    Jul 1, 2020
    29
    68
    36
    Maui
    Name
    Cory Palmeira
    Boat
    19 Alii Kai
    wow, this is a killer build. id the boat based on the old Glasplay's from Washington in the states? 19x9 seems that the beam is a foot wider.
    Thank you. From what I’ve heard it’s almost an identical shape to another tye of boat we have in Hawaii, the glasspro 19 now built by Plastech Hawaii.
     
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    Jul 1, 2020
    29
    68
    36
    Maui
    Name
    Cory Palmeira
    Boat
    19 Alii Kai
    Tried to get a pic of the finish, not spray type finish but still fairly flat with the awlgrip. I’ve heard of methods where you thin it a little more than spec and just rolling but I’d have too much anxiety waiting for all the bubbles to pop.

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