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1993 Starcraft 240 Rebuild

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webermattr View Drop Down
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    Posted: 03/06/2016 at 2:16am
Hello All,

For the past few years, I've been enjoying this forum, but I've never really had a reason to post because 1.) I'm new to boating and have no advice to offer, and 2.) all my questions were already answered in previous postings.

I'm now coming to a close on my rebuild project, so I wanted to share a few pictures.  If you have any questions about materials used or how I did something, please feel free to reply.  Thank you to all the regular readers that have unknowingly given me advice to get through this project :)


I stripped it down to the pontoons and cross members.

I spent the first year rebuilding the powerhead, painting and decals.

I couldn't figure out how to rotate this picture, but this is the new decking.

Here is the new skin in the original railing.  If you want to make your wife happy, work on boat parts in your living room.  Works like a charm.

I used a vinyl weave seagrass type flooring.  My local upholstery shop was able to order it for me.  Our German Shepherds would've destroyed traditional carpet in one season.

This illustrates some of the wiring under the console.  I didn't use any wiring harnesses, I rewired everything from the motor back, and ran it all through water tight flexible conduit.  The wooden box is for the subwoofer mounted to the side of the console.

It's finally starting to look like it belongs in the water and not my yard.  I used laminate countertop material for all the dash accents.

Here is the rear seating and the pop up changing room.  I needed a place to hide the gas tank, so I ended up going with a changing room from another site.  All the other furniture is from PontoonStuff.com

Front seating is super comfortable.  I've found myself hanging out on the boat on warm days while it's still in my yard.  Very happy with the quality of the seats.

Here's the stern ladder I got from PontoonStuff.com - I had to modify the railing system a bit to move it forward and create a swim platform in the rear.  The original design had the railing come all the way back and surround the motor, with a sun deck covering the motor.  

This shows the bimini top, as well as the docking lights and nav lights on the side, all from PontoonStuff.com

Thanks to PontoonStuff for all the quality products and fast shipping!  And thanks to the members of this forum for creating a place for newbies like me to get my questions answered!
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Barnmb7117 View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Barnmb7117 Quote  Post ReplyReply Direct Link To This Post Posted: 03/06/2016 at 2:51am
ClapIt came out really nice. I am going to change my fence panel to the same blue. was it hard to re-skin it? How about turning the corners?
Mike
1993 Tracker fishing barge 21
2015 Evinrude pontoon series 90 hp
Summer - On the wolf River Weyauwega, WI
Winter- Chicago, IL
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Post Options Post Options   Thanks (0) Thanks(0)   Quote webermattr Quote  Post ReplyReply Direct Link To This Post Posted: 03/06/2016 at 3:27am
Thank you. The corners will test your patience. The original skin only came up to the first rail, but I took the new skin all the way to the top rail. These rails have a lip that I could bend back with a putty knife and slide in from the side. Taking it all the way to the top made it more difficult, because I couldn't cut the pieces with all 90 degree corners. They had to be rounded to the contour of the rail. That, in combination with trying to slide the skin through the turns, proved to be very difficult. On the front pieces I ended up cutting off the bottom lip and just sliding it into the top channel and riveting it at the bottom. If you get frustrated and try to force it, you end up kinking the metal, and it could end up looking worse than before you started. Hope this doesn't discourage you, it's definately worth the effort, but it wasn't as easy as I had imagined it would be.
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biguchi View Drop Down
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Post Options Post Options   Thanks (0) Thanks(0)   Quote biguchi Quote  Post ReplyReply Direct Link To This Post Posted: 03/07/2016 at 1:06am
Very nice redo!  I'm doing mine as well.  Got most of the furniture, but am stuck on the speaker installation.  Seems if I were to install speakers in the bases it looks as if the seats will not open all the way and it will be resting on the face plate or the speaker itself.  I noticed you added the sub in the console, but have you added any additional speakers in any of the other seats?
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Post Options Post Options   Thanks (0) Thanks(0)   Quote toonrider Quote  Post ReplyReply Direct Link To This Post Posted: 03/07/2016 at 9:37pm
You did an excellent job on your pontoon, very well done!Thumbs Up I like the looks of the vinyl flooring also, you will have to let us know how it works out for ya. Again, your toon looks great!
Randy
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Post Options Post Options   Thanks (0) Thanks(0)   Quote webermattr Quote  Post ReplyReply Direct Link To This Post Posted: 03/08/2016 at 12:50am
Originally posted by biguchi biguchi wrote:

Very nice redo!  I'm doing mine as well.  Got most of the furniture, but am stuck on the speaker installation.  Seems if I were to install speakers in the bases it looks as if the seats will not open all the way and it will be resting on the face plate or the speaker itself.  I noticed you added the sub in the console, but have you added any additional speakers in any of the other seats?
I did put speakers under the front 2 bench seats.  I used Blaupunkt marine 6.5" that I found on Crutchfield as 'scratch and dent' for a really reasonable price, $50 or so for the pair.  They have a more robust grille so I'm not worried about them being damaged.  The seats do bump up against it when opened, but I don't think it's something to be concerned about.  I put a 2nd Kenwood speaker, like on the console, on the left lean-back, facing toward the stern. I tried to get some speakers ear-level.  The lean-back rests on this speaker when opened, too, but still nothing to be concerned over.


Toonrider - Thanks for that, I appreciate the comments.  I'll be sure to let you know how the vinyl floor holds up.
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Post Options Post Options   Thanks (1) Thanks(1)   Quote p3cflyr Quote  Post ReplyReply Direct Link To This Post Posted: 03/08/2016 at 1:21pm
Just excellent.  Very neat wiring.  Interesting use of materials not normally used on pontoon boats.  I really like what you have done.  Triple tube??
Mike

"Atta Boy" Award June 2011
1987 Lowes Fish and Fun 20ft
1999 Merc 50hp 4 strk big foot
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Post Options Post Options   Thanks (0) Thanks(0)   Quote webermattr Quote  Post ReplyReply Direct Link To This Post Posted: 03/08/2016 at 10:44pm
Originally posted by p3cflyr p3cflyr wrote:

Just excellent.  Very neat wiring.  Interesting use of materials not normally used on pontoon boats.  I really like what you have done.  Triple tube??
No just 2. I got the boat, motor, and trailer for $2500, so I can't complain.  I might add a 3rd after this season depending on how well it performs as is.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote jonwinters21 Quote  Post ReplyReply Direct Link To This Post Posted: 03/28/2016 at 9:36pm
Great looking boat!  Also love the Lake Norman area.  Could you tell me where you bought your paneling from?  I am having trouble finding paneling tall enough to fit the back end of my pontoon. 

Thanks in advance,

Jon
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Post Options Post Options   Thanks (0) Thanks(0)   Quote webermattr Quote  Post ReplyReply Direct Link To This Post Posted: 04/06/2016 at 2:53pm
Jon,
I found the paneling online at Pontoon Specialists.  Thanks for the compliment.
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Post Options Post Options   Thanks (0) Thanks(0)   Quote SteveM54 Quote  Post ReplyReply Direct Link To This Post Posted: 06/03/2016 at 6:33pm
Nice job on the whole rebuild.ClapBig smile

I have to do a complete rewire on my build and was wondering about your use of the water tight flexible conduit. I was going to use the type with a slit down the side & install it slit side down so any water could drain out but if I use your idea did you cluck the open ends or do they make a end cover or ?

I totally love your console. I have the same set up with the shiftier type and am really having a problem finding the same size panels to replace all the switches and gauges with. i spend more time looking for parts than I do working on the boat. Confused

Did you paint the inside fence panels black or is it just the angle of the picture? Painting mine black inside with yellow outside would solve a couple of problems but not sure how to go about it. I don't want to replace the sheets - just sand of the old decals & repaint. Cry

Thanks for posting your work, I already snagged a couple of ideas from you.............

Steve
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Post Options Post Options   Thanks (0) Thanks(0)   Quote Something2do Quote  Post ReplyReply Direct Link To This Post Posted: 06/03/2016 at 7:09pm
Nice build. Looking forward to your future upgrades. 

If you don't mind me asking, where did you get your top mount control/shifter? I need a similar model so I can move my control handle away from my steering column. 


1990 30' Party Hut Rebuild 110hp Evinrude
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Post Options Post Options   Thanks (0) Thanks(0)   Quote webermattr Quote  Post ReplyReply Direct Link To This Post Posted: 06/13/2016 at 9:14pm
Stevem54 - I used flexible conduit from a residential hardware store. I think it's more designed for running power to a/c units and things like that, but it worked well for me. There are feed-through bushings that have straight or 90 degree elbows. They're made to go through electrical boxes, but they're standard npt, so a little creativity in the plumbing isle and I'm sure you'll put together something you can use. I didn't paint the panels, they're dark blue inside and out, probably just the angle. Thanks for your comments!

Something2do - I'm not entirely sure where I got my top mount controller. It's made by sea star solutions, and they also make replacement control cables, too. They do have options to use your existing cables, but mine really needed to be replaced anyway. I realized this immediately when the new ones came and I saw how much easier it was to slide the cables compared to the old. But if you search for "sea star solutions top mount" that should push you in the right direction. Hope this helps!
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Post Options Post Options   Thanks (0) Thanks(0)   Quote RonHolton Quote  Post ReplyReply Direct Link To This Post Posted: 04/04/2018 at 1:11pm
Nice boat.  Doing a 1996 myself.  

The vinyl weave seagrass type flooring.  What upholstery shop was able to order it and how much for the carpet and install?  If you don't mind me asking.  Looking for a part number for the color and type of carpet so that I can source locally near Raleigh.

Thanks!

Ron H.
Wake Forest, NC


Edited by RonHolton - 04/04/2018 at 1:19pm
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Post Options Post Options   Thanks (0) Thanks(0)   Quote toonrider Quote  Post ReplyReply Direct Link To This Post Posted: 04/05/2018 at 2:46am
Originally posted by RonHolton RonHolton wrote:

Nice boat.  Doing a 1996 myself.  

The vinyl weave seagrass type flooring.  What upholstery shop was able to order it and how much for the carpet and install?  If you don't mind me asking.  Looking for a part number for the color and type of carpet so that I can source locally near Raleigh.

Thanks!

Ron H.
Wake Forest, NC

Here is a site you may want to check out. I am sure there are others if you google it.
http://stores.ebay.com/BoatCarpetSales?_trksid=p2047675.l2563
Randy
2008 SunTracker 190
2008 Mercury 60hp Bigfoot
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