And... yet another skipjack rebuild. Help needed

URN

Almost A Member
  • Feb 20, 2018
    197
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    Anchorage
    Name
    URN
    Boat
    Whaler 25
    A few photo updates. Just working on cutting the stringers to fit properly. The center two will be full height. The outer stringers will remain stock height except for where I will be building fish boxes. The bilge area has the center stringers cut lower for access. You will see this come into play later on when I build shelf's for mounting pumps in the bilge. Hopefully have the stringers bedded in next week. I'm going to focus on leveling the boat today and getting the glass precut. I also have several more jigs to cut for keeping the stringers centered and parallel. I used foam as all my templates. It's very easy to cut and shape and make adjustments. Then it gets transferred to the coosa and cut.

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    These rebuilds are long and tedious. I've rebuilt two whalers and I am done with projects for a while, at least that's what the wife wants!! Keep the pics and progress coming. Getting feedback on these things does help keep the motivation up.
    One question that is obviously too late now, but may help with the deck later is if you've thought of using a vacuum pump to hold and secure core and laminate in place? I'll attach a couple pics of the outer skin and core being vacuum bagged in place to squeeze them tightly together on my whaler transom rebuild. The other one is part of a deck lid where I reused the upper skin and redid the core and underside laminate. It reduced weight and held things together way better. Costs were reduced by using the 4 or 6 mil greenhosue plastic and butyl tape from Home Depot. Its not very stretchy but it is cheap. I used a $80 amazon vacuum pump and it ran all night multiple times. I also made deck inserts and covers where the vacuum bag forced the first layup to wrap around the edges. After some cleanup the layup on the other side wrapped around to "encapsulate" the core. Hopefully that makes sense.

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    Reel hip

    Meet my "Well known Member"
    Feb 19, 2008
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    Name
    Doug
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    25ft Skipjack fly
    Wow..... I'm worn out looking at what has been done. More wore out thinking what needs to be done.

    Josh your work looks really good! When its done you will literally know it inside and out.
    Keep it up!
     
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    Basscatjosh

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    Jun 14, 2018
    65
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    Nor cal
    Name
    Josh
    Boat
    Basscat Pantera classic, trophy cc, Cajun, jonboat, trident 13 ocean kayak
    I haven't updated in a while so I thought I would add some picks. I am just finishing up the front portion of the stringers underneath where the cabin used to be. I capped the stringers outside the boat where it's easier to work. Then cover the sides when I am tabbing them in. Except for the full height stringers in areas that will be supporting the floor. In those areas I will rely on the thickened epoxy to seal the top if the coosa. I should be done with the stringers completely by the end of the weekend and then I can move on to getting the gas tank fitted and adding bulkheads throughout. I'm excited to start all the under deck components. I'll be doing all the plumbing, seacocks, pumps and building the insulated killbox.

    The outboard bracket should be getting finished up any week now and once I get that on the boat I can mark all the bolt holes and start planning the floor and scuppers. AandJmarine also known as custommarinewelding has been awesome with helping design and build my bracket.

    I'm also redesigning the cabin to make a little more head room. I'm dropping the seating area a good 10" so that I can sit up straight. The Skippy has no headroom in the cabin, it's designed to lay inside only, atleast up front. I'll be spending a lot of time in here with my son and wife so I'm lowering the seating area and also extending the cabin back another foot or so. This will involve redesigning the dash and moving the helm back another foot. That will give me a nice area under the helm where I can have a designated electrical cabinet without losing cabin space.

    I can finally say I'm done with most of the cutting and grinding!! I don't think there are many things on earth more miserable than grinding a fiberglass hull in the summertime. Now that the weather has cooled off it's not as terrible but now it's starting to get too cold for the epoxy. I'll be tenting the boat in the next week or so. That way I have the option to heat the tent on layup days. I'll post back in a few weeks with some more progress hopefully.

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    Basscatjosh

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    Jun 14, 2018
    65
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    Nor cal
    Name
    Josh
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    Basscat Pantera classic, trophy cc, Cajun, jonboat, trident 13 ocean kayak
    It rained last night so I couldn't do any glass work. Decided to pressure wash everything inside the boat. I didn't realize how bad my pictures were I posted yesterday until I viewed them again. Here are some pictures of the progress after the pressure washing.

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    bob311

    Newbie
  • Dec 7, 2018
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    huntington beach
    Name
    bob
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    23' sanger alleycat
    Great progress and workmanship. If I might ask you a question, why did you use 1708 with epoxy resin, was it only to create a thicker/ heavier laminate? also i'm not sure if any one has mentioned this, but my friend made this mistake years ago. Poly and Vynlester resins will not bond to epoxy well. So if you decide glass anything to the expoxy that is covered in poly like the deck or floor it has to be tabbed in with epoxy for a good bond. Looking forward to see the end result, keep up the good work!
     
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    Basscatjosh

    Newbie
    Jun 14, 2018
    65
    58
    Nor cal
    Name
    Josh
    Boat
    Basscat Pantera classic, trophy cc, Cajun, jonboat, trident 13 ocean kayak
    I went with 1708 and epoxy for ease of use and potential for success. Yes, I chose 1708 over straight biax for thickness and strength. I don't know a whole lot about very large fiberglass projects so I went with the combination that everyone seems to agree is sufficient in strength. I read many comments on why this combo was overkill and not necessary and overly expensive but no arguments about the strength and durablility about this combo. Ultimately that was why. I was also aware about the poly issue and knew that I would have to paint instead of gelcoat.
     
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    Basscatjosh

    Newbie
    Jun 14, 2018
    65
    58
    Nor cal
    Name
    Josh
    Boat
    Basscat Pantera classic, trophy cc, Cajun, jonboat, trident 13 ocean kayak
    Progress update. Northern California got cold a few weeks ago and brought progress to a grinding halt. Can't fiberglass in these cold temps. I have the boat in a large enclosed tent now and I can heat it and resume work. Stringers are all tabbed in. The full height center stringers have 4 layers of tabbing and the smaller outer stringers have 3 layers of tabbing. I only put one layer over the tops of them. I left a lip of the original tabbing in the most forward area where the stringers came to an end. It gave me a convenient jig for holding them in place and seemed like a place where some extra thickness would be good for the pounding she will be taking offshore. I filled it with thickened epoxy before I set them in place and then removed the excess.
    I used up all the materials and ordered more glass and epoxy. I used 40 yards of 50" wide 1708 and 14 gallons of epoxy just in the transom and stringers. I actually ended up 3 yards short of material to finish the most forward section of stringers.

    So for anyone wondering about materials, 43 yards of 1708, 16 gallons of resin, 3 gallons of cabosil, and probably 4 pounds of 1/4 chop strand, 3 sheets of 1.5" coosa, and a single sheet of 3/4" coosa. That's my material list for transom and stringers only. There was some slight waste in materials when I mixed too much product, or in cut offs from the fiberglass but not much. I do also have some decent size pieces of coosa left that will be used in the future. Including sand paper and various types of cutting blades, and everything else I'd estimate in the $4k range.

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    Basscatjosh

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    Jun 14, 2018
    65
    58
    Nor cal
    Name
    Josh
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    Basscat Pantera classic, trophy cc, Cajun, jonboat, trident 13 ocean kayak
    A few more pics. I sanded out all the holes in the transom and opened them up so that I could hopefully avoid any haloing through the paint. Does this seem sufficient or should I add a layer of glass over the entire area? I'll post again when I have something worth reporting. Thanks for following along guys.

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    Fishbones

    Your wife thinks about ME
    Nov 7, 2005
    8,477
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    Chula Vista
    Name
    Rich
    Boat
    One Off 28' Custom Built Skipjack (SOUTHWESTERN) & 18' Sylvan (Short Runs)
    You need to put a little piece of glass over each hole or it will halo eventually.
    I use a 4” disc grinder with 80 grit to dish out the holes a little.
     
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    SkipJack Boats

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    Jul 8, 2020
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    Oak Hills, CA
    www.skipjackyachts.com
    Name
    Michael Englebrecht
    Boat
    25 ft Skipjack
    She looks rough but I think she will be better than new somesay. Some back story on the boat. She was in a field in the middle of nowhere and the farmer that sold it to me had to drag it out with a tractor. All 4 tires and rims were shot, I had to bring wheels when I went to pick her up and we swapped them out in the dirt. The farmer had a air compressor and impact, thank God. Lugs were all Rusty and would have been an nightmare by hand. Him changing the wheels out and dragging it out of the field was worth the $100 I paid him for the boat. Bearing buddies accepted grease and she towed just fine over 2 hours back home. Going to repower with an Armstrong bracket and 300 Suzuki. Hope it's enough power to push her sufficiently.
    Did you and I speak about this boat?
    BigMike
     
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    Basscatjosh

    Newbie
    Jun 14, 2018
    65
    58
    Nor cal
    Name
    Josh
    Boat
    Basscat Pantera classic, trophy cc, Cajun, jonboat, trident 13 ocean kayak
    Made some more progress, it seems like the more progress that's made the more work that reveals itself. I'm pretty much done structurally with everything under deck. Gas tank shelf is glassed in and lined with hard rubber, all the structural bulkheads are also in. Have to finish building my fishbox and mounting shelf's for pumps and then it's just as simple as plumbing and thru hulls. Bracket will be here first week of February, sourcing a Suzuki 350 duoprop as we speak. Decided she's getting a Pilothouse before she ever splashes water so that adds a couple months. Here are a few more photos. Have the boat completely tented and a 125,000 btu diesel heater to keep the temps up for fiberglassing. Six t5 led lights keep me working after dark. Quick question to anyone with a skipjack 24, am I making a mistake raising the Pilothouse floor 5"? The Pilothouse will be completely enclosed with door so I was hoping to keep water out and raise the seating position so I can see over the 16" simrad going in the helm.

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    Basscatjosh

    Newbie
    Jun 14, 2018
    65
    58
    Nor cal
    Name
    Josh
    Boat
    Basscat Pantera classic, trophy cc, Cajun, jonboat, trident 13 ocean kayak
    You need to put a little piece of glass over each hole or it will halo eventually.
    I use a 4” disc grinder with 80 grit to dish out the holes a little.

    That's what I thought. Working on sanding the transom currently. That bottom paint is a mother to sand off. I think I may lay one full sheet across the back and cover everything. Or just patch them individually, not sure yet.
     
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    Basscatjosh

    Newbie
    Jun 14, 2018
    65
    58
    Nor cal
    Name
    Josh
    Boat
    Basscat Pantera classic, trophy cc, Cajun, jonboat, trident 13 ocean kayak
    DUDE! that looks killer! do us all a favor and keep a paper template or dimensions sketch of your pilot house build. I will for sure send you 50 bux for a detailed plan set and material list.

    Thanks man! I'll do my best to keep posting about dimensions and my reasoning for how I intend to do it. I'm thinking it will be a mix of nidacore and coosa for materials.
     
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    Basscatjosh

    Newbie
    Jun 14, 2018
    65
    58
    Nor cal
    Name
    Josh
    Boat
    Basscat Pantera classic, trophy cc, Cajun, jonboat, trident 13 ocean kayak
    I forgot to mention a couple things about the design. For one you will notice the cabin seating is lower than original. I did this for headroom, but you do lose significant width as the hull closes quickly towards the keel. The gas tank is lower and longer than original so it sits over a foot forward of the original but ends in the same location in the rear. Puts the weight lower and forward. The gas tank shelf is angled up towards the bow to always keep the pickup slightly lower. Only an inch lower adrift but pretty level on the trailer for fillup. My fish box will be fully insulated and plumbed with whaler diaphragm pumps for evacuation but will also have a very large fill pump as well. I calculated I can add 900 pounds of water below the deck for ballast when it gets rough. Here in northern California weight is actually more important than speed most of the time. We live in some weird bizarro world where the only reason I'm getting the Suzuki 350 duoprop is torque and lift not for horsepower. And because I want that 5 between the 3 and 0. I can't think of anything else right now but I'll update in a few weeks. Parts and material costs currently around 15k. That's including the bracket. Seems going rate for Suzuki 350 duprop 25" shaft in white with controls is roughly 32k installed. If anyone has a lead on a much better price, I have boat and will travel. Lol
     
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    Hismosa

    I Post A Lot But I Can't Edit This
  • Oct 15, 2016
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    Name
    Glenn
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    Boats n hoes
    Quite a bit of poor reviews about the 350. Don't think they have that motor dialed in yet. Wouldnt want to do all this work and then end up in the shop most of the time for motor repairs.
     
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    Basscatjosh

    Newbie
    Jun 14, 2018
    65
    58
    Nor cal
    Name
    Josh
    Boat
    Basscat Pantera classic, trophy cc, Cajun, jonboat, trident 13 ocean kayak
    Quite a bit of poor reviews about the 350. Don't think they have that motor dialed in yet. Wouldnt want to do all this work and then end up in the shop most of the time for motor repairs.

    Your not the first person to say that to me but when I try to find reviews about it most are praises. Is there any specific threads that you know of so I can read along. I definitely don't want to do all this work and have it sitting in a shop while the fish are running. Anyone else have any specific issues with these motors? I know that the breakin period for the 350 is extremely important. Also the higher compression could cause issue with low quality fuels. Any first hand accounts from people I'd really love to hear. Suzuki isn't big on the west coast so the last thing I want to deal with is warranty issues.
     
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    bob311

    Newbie
  • Dec 7, 2018
    60
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    huntington beach
    Name
    bob
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    23' sanger alleycat
    I have a couple friends with rhe 300 duoprops and have had zero issues. You might want to look at thay instead. Just like yamaha has a bullet proof 300 their 350s were breaking cranks
     
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    Basscatjosh

    Newbie
    Jun 14, 2018
    65
    58
    Nor cal
    Name
    Josh
    Boat
    Basscat Pantera classic, trophy cc, Cajun, jonboat, trident 13 ocean kayak
    Realized I haven't updated in a while. Raised the floor of the bilge using cut up pieces of the original floor fiberglass. I hate that most bilges always hold some water. This skippy will drain every drop. Also used the original floor fiberglass to make the fishbox floor covering the insulation. Used the original scuppers to make the drain for the fishbox. Bracket came in and it is beautiful! AandJmarine did a killer job! I had them add handles around the sides for tie down points for coolers, livewell, etc. Painted most of the under deck areas. Gas tank is sitting permanently on 1/4" thick firm rubber. I've been rebuilding a buddies transom on a 25 steiger so I'll end up losing a few weekends. Should be back to working on it in a couple weeks. Next step is plumbing, thru-hulls, fuel lines and then glassing in the floor. Then I'll start building the helm and running electrical.

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