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1987 Party Hut 28DL rebuild begins....

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    Posted: 07/17/2020 at 8:27pm
the back story.....lol:

2 years ago we sold our 22' pontoon to make the down payment on a lake house. Since then we have been airbnb'ing the house so we get very little "LAKE TIME". A year ago we decided on a Party Hut so we could moor it at our dock, then go use it whether or not the house was occupied and camp on it overnight anyplace we like. 

I looked at some rough boats, most over $8K and even the ones around 15K needed attention. My biggest parameter was a four stroke engine 90hp or above and those seem to be hard to find on the Hut's but we found one. A 1987 28' DL with a 2008 Honda 115 Four Stroke on a original tandem trailer. The engine runs great, but the roof is rotted bad and there are soft spots on the main deck. The last time the boat was in the water was 2011. Trailer surge brakes are non working, but I did put 4 new tires and rims on it and drove it home for $6K.....now the work begins. 

Sorry, pic's will not load right now, will try again later.

Also, the boat has the original binnacle on it and I cannot figure out how to remove it. Specifically the black plastic cover that the shifter handle attaches. I have removed the screws but it does not budge. From underneath I see 4 wood screws(2 at top and 2 at bottom) that are hiding under that plastic cover....any ideas?



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Post Options Post Options   Thanks (0) Thanks(0)   Quote Motor7 Quote  Post ReplyReply Direct Link To This Post Posted: 07/18/2020 at 11:39am
On the way home


Home

Already heaving the old seats and console 'overboard'


Edited by Motor7 - 07/18/2020 at 11:46am
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A blank slate:


the rotten roof which is 1/2" ply:


Back corners were a little rough:







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Post Options Post Options   Thanks (0) Thanks(0)   Quote Motor7 Quote  Post ReplyReply Direct Link To This Post Posted: 07/18/2020 at 11:54am
Binnacle dissection. I was wrong, it is a Honda Binnacle. The plastic cover has 4 small holes around the perimeter that snap over 'nubs' on the binnacle base plate. Once the cover was off I had enough slack to pull it out and remove the cable cover. Each cable is held in by a 'C' clip. 





The console was rotten so I marked all connections, removed the gauges/switches and tossed the console:


I removed all of the roof plywood and carpet.....nasty job. I start on the walls and fence today.


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Post Options Post Options   Thanks (0) Thanks(0)   Quote Motor7 Quote  Post ReplyReply Direct Link To This Post Posted: 07/19/2020 at 1:01pm
Ok, I found that the original deck is 3/4" but the roof was 1/2"

Should I go back with the original thicknesses, or should I use 3/4 on the roof? I was kinda surprised that the roof rafters were spaced 24" apart and they used 1/2".....that is really a no no.

So if I weld in extra box rafters making the roof 12" on center, then go with 1/2" I wonder if the weight difference compared to using 3/4 on 24" centers is worth the hassle??
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Motor7 Quote  Post ReplyReply Direct Link To This Post Posted: 07/19/2020 at 1:05pm

Also, the original console windshield is perfect. If anyone wants it just pay shipping.


Edited by Motor7 - 07/19/2020 at 1:07pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Motor7 Quote  Post ReplyReply Direct Link To This Post Posted: 07/20/2020 at 10:54am
Anyone?....Anyone?...Bueller?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Motor7 Quote  Post ReplyReply Direct Link To This Post Posted: 07/20/2020 at 10:59am
Y'all are a quiet group....maybe more pics?







I found that cutting the old ply lengthwise then getting a breaker bar under it and 'popping' the boards off the rusty screws works with some effort:

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Post Options Post Options   Thanks (0) Thanks(0)   Quote curtiscapk Quote  Post ReplyReply Direct Link To This Post Posted: 07/22/2020 at 7:53pm
Nice can't wait to see it finished!Tongue
Craig n Paula
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Motor7 Quote  Post ReplyReply Direct Link To This Post Posted: 07/24/2020 at 8:51am
Picked up the plywood and "SeaGrass" woven vinyl from Leisure Kraft Mfg in Cookville. They make their boats right their from the ground up.....The log tube bending machine is awesome. They also sell build accessories like screws, corner trim, glue and have a lot of accessory parts stocked in their showroom. Talked to the guys while loading the Ply and they said they are slammed, no boats for sale on the lot as all of them are being built on backlog order right now for customers. 

Missing some fence edging pieces that are 2.5x3.5.....hope to run them down tomorrow at a aluminium supplier. Also, my spool gun arrived, now I just need wire and some brushes and a new bottle of Argon gas. I have new scrap to practice on and of course I watched Utube instructional videos so I think I can do it...hold my beer. 

Who would have thunk that in the middle of 'rona2 one could hear.... "Honey we are out of toilet paper and the store shelves are bare!" "That's ok snookums, our new pontoon boat in ready for pick up tomorrow!" AHhhh, but what better way to get some clean rona free air?...on the WATER!




Edited by Motor7 - 07/24/2020 at 8:52am
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I'm using a eraser wheel to get the bulk of the decals off the fencing. Then hitting it with a spray on stripper from Home Depot:


This is a slow messy process but it has to be done.

Also, the short sections of plywood under each pontoon nose was rotted. This is where the cleats are mounted so I had to un-bolt the whole brace/rail assembly and remove 4 rivets from each side to get them off.

Another thing I found is that the pontoons are not square to the Z braces and are off by over 2". I walked around the boat several times yesterday taking measurements and studying the problem. It looks like it came right out of the factory that way because I do not see any witness marks from shifting. Anyone else seen this issue? 

And leave this alone, or heat it and try and bend it back?


And a test paint panel...Tan over Teal:





Edited by Motor7 - 07/28/2020 at 2:00pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Motor7 Quote  Post ReplyReply Direct Link To This Post Posted: 09/20/2020 at 12:58pm
Sorry, but this site is way too quiet so I restarted my build thread on another popular 'toon forum. Boat is in the water and 90% done. Cabinets, furniture arrangement and other little things will get done this winter. 








Edited by Motor7 - 09/20/2020 at 1:00pm
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