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1986 Playbouy rebuild

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Stevehue View Drop Down
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    Posted: 04/15/2014 at 9:11am
Well started this project and now think that I may have paid a bit to much for it because we are doing more work than planned. In the end though I know I will have a nice boat but still wish i would have been a bit more thorough when looking at this boat. It is what it is though so now it is a matter of making it a boat that we can enjoy. I have pulled all the furniture and besides a few seams being ripped it is not in to bad of shape and cleaned up nicely. I plan to pull the motor sometime this week and then start on the wiring and deciding how we are going to put it back together. I bought the flooring kit which I think was the smartest thing to do even though it is a bit more expensive. The problem I had is nobody around here, including lumberyards, carry CCA plywood it is all the AB stuff. I don't want to do the flooring again so the extra expense was worth it. 

We plan to eventually replace the furniture in a couple years maybe the motor also. I am mechanically inclined so nothing here is beyond my ability unless it is maybe a motor rebuild. If it wasn't snowing in mid april I maybe able to get more done!!!ConfusedThumbs Down

Here are some pictures that I have taken. I will post more as I go along.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 04/15/2014 at 9:50am
it only took me a whole season lol!

Dang motor!


Great start!
Craig n Paula
THE FLOATER Rebuild
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Stevehue View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 04/15/2014 at 11:01am
Well the wife wants to be on the water by june!!!Censored  It is only a 40 HP motor so I don't believe it is that heavy really. I just need to figure out how I am going to store while I do the rest of the work.

Anybody have a good rig to keep the motor upright until it goes back on the boat?? I am thinking some type of saw horse  rig.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote badsign75 Quote  Post ReplyReply Direct Link To This Post Posted: 04/15/2014 at 12:36pm
a 55gal drum works also........theres nothing wrong with the AB plywood it just means its knot free ( could be a better choice)

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Stevehue View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 04/15/2014 at 2:02pm
Originally posted by badsign75 badsign75 wrote:

a 55gal drum works also........theres nothing wrong with the AB plywood it just means its knot free ( could be a better choice)


From all that i read is that AB is not the right stuff because it is not pressure treated like the CCA which is not the same as pressure treated lumber you buy at the big box stores. What was on the pontoon was CDX which now after 6-7 years needs to be replaced. CCA seems to be what most people recommend so for the few extra bucks I am going with that. I hope not to have to do this again in 6 years or so.!!


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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 04/15/2014 at 2:14pm
cca should be good for 20+ years.Clap
Craig n Paula
THE FLOATER Rebuild
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Post Options Post Options   Thanks (0) Thanks(0)   Quote bjennings79 Quote  Post ReplyReply Direct Link To This Post Posted: 04/15/2014 at 2:51pm


I built this one out of scraps. It's really sturdy and easy to build.

Here are the plans.


Engine Stand
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Stevehue View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 04/15/2014 at 2:55pm
Thanks i may have enough scrap laying around to do that!!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote fatdaddy Quote  Post ReplyReply Direct Link To This Post Posted: 04/16/2014 at 8:37am
Here's the one I built!
 
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Stevehue View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 04/20/2014 at 9:49am
Well with a little, let me emphasize little help, from the family we got the motor off. Well basically I bear hugged it while they kind of just looked at me and said we thought you needed help!!Confused Anyway down to the skeleton now. Going to replace the transom and then start to put it back together. Any suggestions on the transom?. I know that I will have enough CCA left to do it. I was thinking 3 pieces glued together.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote p3cflyr Quote  Post ReplyReply Direct Link To This Post Posted: 04/20/2014 at 11:38am
I used scrap CCA for the transom.  Enough glued together to fill the void.  I glued, then screwed and finally covered all sides and edges with epoxy (auto kind) for water proofing. That was 6 years ago and no probs to date. Also silicone the motor mount holes heavily before putting the bolts through.  Stop any water infiltration into the transom wood.  My 2cts only.


Edited by p3cflyr - 04/20/2014 at 11:40am
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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 04/20/2014 at 10:18pm
x2 I used 2 layers scrap with construction glue and 20 screws. If you want pics check page 7 of my rebuild in my sig.
 
Good luck!
Craig n Paula
THE FLOATER Rebuild
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Post Options Post Options   Thanks (0) Thanks(0)   Quote p3cflyr Quote  Post ReplyReply Direct Link To This Post Posted: 04/21/2014 at 12:22am
I forgot to specify stainless steel screws for the transom.  also anyplace that water is possible..  
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 05/04/2014 at 5:18pm
Well the floor is down and the carpet is on. Definitely making some progress. Really glad I went with the kit because it has made this so easy!!!
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Post Options Post Options   Thanks (1) Thanks(1)   Quote nathan Quote  Post ReplyReply Direct Link To This Post Posted: 05/04/2014 at 9:15pm
looks great!!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 05/14/2014 at 10:13am
Ok come on weather let stop the rain. I thought it was april showers bring may flowers!!!Angry It has had a chance of rain everyday i think so far in may. I have some furniture back on the boat but it has been covered for the last couple weeks.  I am hoping this weekend proves to be decent and i hope to have all the furniture mounted then comes the wiring!!!Censored
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 05/20/2014 at 9:47am
Well the furniture is mounted for the most part and we did the railing paneling last night. I am a bit disappointed with the aluminum paneling not because it was hard to work with but because it seems very fragile. After the few first pieces we realized this and tried to be super careful installing it but we still ended up with scratches and dents. It is what it is though so I will definitely think twice using it again. Luckily we have some left over so if any of it gets destroyed, which we fear inevitably will happen, we can replace it. 

So anyway the furniture went back easily and we reused the furniture. Big cudos to my wife who literally scrubbed her fingers raw cleaning them. We have a few that the seams split but we plan to replace them all in a couple years. Tonight i am putting the railings on then it is on to the wiring, motor and the rest. It is coming to together pretty nicely and hopefully i will have it done in a few weeks.




Edited by Stevehue - 05/20/2014 at 9:48am
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Post Options Post Options   Thanks (1) Thanks(1)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 05/20/2014 at 10:34am
Wow I can't believe those are the same seats!!! She did great! Nice rebuild.
Craig n Paula
THE FLOATER Rebuild
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 05/20/2014 at 10:55am
Thanks!! I know she worked hard. I guess it just came down to that if we replaced the furniture then we definitely paid to much for the boat. We figure if we can get a few years out of them then we will feel better about the price we paid. Even though the aluminum paneling is not we expected it does look good. I hope to have it all in place tonight and will have some pictures in the next few days.
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Looking good! It's hard to imagine that those are the same seats that were in the earlier pics. Great job!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 05/26/2014 at 10:22pm
So I was able to get the siding on and railings mounted. All the witing is done for the most part. I got the motor to start but then noticed no water coming out. Found the tube clogged and cleaned that out but no luck so pulled off the lower unit and the impeller was fried. I am going to order anew kit tomorrow. Going to wire the trailer this week while I wait for a new water pump kit. It is getting there and hopefully I will get the part in so we can have a maiden voyage next weekend.

Edited by Stevehue - 05/27/2014 at 12:33pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 06/02/2014 at 10:26pm
Well put on the new water pump and fired it up. It runs really good which is a big weight lifted because we had our doubts due to some of the other stuff that has happened. I put it in gear and it it went right in and worked great. The new control box is really nice. Still trying to figure out the push to choke but it does have a manual choke which is good. Hopefully if weather permits I will have a maiden voyage video up next week.

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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 06/03/2014 at 12:41pm
awesome!
Craig n Paula
THE FLOATER Rebuild
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 06/09/2014 at 9:07am
Hey it did not sink!!!!ShockedThumbs Up  Finally on the water. Took it out for some test runs this weekend and everything seems to be in decent shape. Some minor adjustments to the shifter cable and the steering seems a little stiff but for the most part she ran really good. Still have some finishing touches left which I plan to finish this week. I have a video that I will post this week also. I am going to try to stitch up the furniture also it seems that duct tape has one job that it is not very good at!!!

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Post Options Post Options   Thanks (0) Thanks(0)   Quote fatdaddy Quote  Post ReplyReply Direct Link To This Post Posted: 06/10/2014 at 8:52am
Very cool...Congrats!!!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 06/10/2014 at 9:42am
Nice job! Great editing on the video as well!
Craig n Paula
THE FLOATER Rebuild
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 06/14/2014 at 11:56pm
Well after all this we found we have leaking tubes. From a high of getting almost finished to this. Both seem to have a decent leak as it seemed a couple gallons came from each. It did take about 3 times out to get this much water and they do have plugs at the back of each tube so its not a game ender but just another hassle. Looking at every thing on the internet welding seems the only solution or more the best solution. Now I guess its fig.uring out ahere togo from here. I have to much invested to not be get them fixed butnot sure of just replacing the tubes is the better way to go. It still floats and I am not in fear of it sinking but man this just sucks.

Edited by Stevehue - 06/14/2014 at 11:59pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote fatdaddy Quote  Post ReplyReply Direct Link To This Post Posted: 06/15/2014 at 8:54am
Build your self a pressure tester and put about 2psi in toons ans start spraying them with soapy water....the leaks are most likely towards the rear, a lot of times right near the deck supports....you can build the the pressure tester for less than ten bucks...I am having similar issues myself right now....Hope this helps, here is a picture of what I made!!
 
Keith Winders
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My 1989 SYLVAN REBUILD
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88HP Johnson
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Stevehue Quote  Post ReplyReply Direct Link To This Post Posted: 06/15/2014 at 10:10am
Luckily I have a air valve on top and plugs at the bottom so I should be able to rig something. I am just kicking myself because I had it stripped down and I should have been checking it then. I guess I was just hoping that with all the things wrong that the tubes would be good which we were told they were but still bought it as is. So now it is what to do from here. Pay to have it welded or use some type of coating. I have read that people are using rhino coating and other stuff but I am thinking this is a temporary fix more than anything. I am thinking of staying away from JB weld and stuff like that. Muggy weld seem a decent alternative since it looks more like brazing which I have experience with and also own an oxygen acetylene torch. Any body ever try it or use it? 

Edited by Stevehue - 06/15/2014 at 10:12am
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