Forester 20' rebuild

[Comstocker]

After 14 yrs of summer use without benefit of a cover it's finally time for a rebuild. As part of the rebuild we're also going to change the furniture layout as we don't fish from the 'toon anymore. Here's a pic of what we're starting with, the flip-flop bench had a live well in it. We're thinking of re-using the flip-flop bench (minus the backrest) as a cooler/ottoman that we can push around as needed.

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Stuffed it in the garage and started pulling off the old furniture

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Getting close to the deck!

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Tonight we should finish pulling off the old console and start hole drilling all the deck screws out. Hope to have the old deck off tonight, then we can start working on putting it back together! I'll do some site searching to find out the best way to pull the steering wheel and cabling. I also have to start calling local suppliers for Marine-grade plywood.

Look forward to sharing the rebuild. The only issue we've had so far was the bolts that hold the fencing on. They were long bolts with the three-finger style anchors that you hammer into a drilled hole and the plywood had rotted so they just spun. We had to drill the bolt head off and push them down through the decking. Thankfully the builder didn't use stainless hardware, so it was easy drilling! Have to buy some more beer and get back to it after work tonight!

[HandymanHerb]

Good deal keep the pictures coming on the rebuild

[curtiscapk]

Welcome! Don't forget we get a 10% discount from pontoonstuff.com

[sunedog]

Tonight we should finish pulling off the old console and start hole drilling all the deck screws out. Hope to have the old deck off tonight, then we can start working on putting it back together! I'll do some site searching to find out the best way to pull the steering wheel and cabling. I also have to start calling local suppliers for Marine-grade plywood.

You may not have to disconnect your steering cables and motor controls. I was able to loosen everything up and lay the console on its side on a support right next to my deck. Read this viewtopic.php?f=2&t=15791

[Bamaman]

Last time I redid the carpet on my 1985 Starcraft was about 7 years ago--when it was about 22 years old. Since the marine plywood only had two small pieces on the rear that were rotted, I didn't think about replacing the rest of the wooden deck. That job would have been really tough to do, with the plywood riveted to the crossmembers. It was a big enough job just getting the fencing and seating off to recarpet.

I'm saying that if your marine plywood is still good, don't fix what's not broken. If your plywood needs replaced, the only thing to use is marine grade. I was looking locally, and we actually have a plywood dealership selling all kinds and sizes of plywood--including marine grade.

Good luck to you on your project. My recarpeting took me about two weekends.

[redbeard]

Good start on the rebuild have fun and keep the pics coming.

[Comstocker]

You may not have to disconnect your steering cables and motor controls. I was able to loosen everything up and lay the console on its side on a support right next to my deck. Read this viewtopic.php?f=2&t=15791

We're putting a new console on as well so I have to pull all the cables and controls from the old console. That steering wheel is really on there!

[Comstocker]

I'm saying that if your marine plywood is still good, don't fix what's not broken. If your plywood needs replaced, the only thing to use is marine grade. I was looking locally, and we actually have a plywood dealership selling all kinds and sizes of plywood--including marine grade.

Good luck to you on your project. My recarpeting took me about two weekends.

Thanks for the well wishes! The old plywood is starting to rot around the edges, the old hardware just spins in the wood. The local Menards wants $69.99 a sheet for 3/4" marine plywood, and we need 5 sheets. We're going to check a couple other sources as well. We figured if we change it all now and buy a good cover for it we'll be good for a long while!

[fergusmj]

I agree with just spending the extra couple hundred and replacing it now. Better to do it now than have to do it again in a few years if the other ones go bad.

Just my opinion though.

[Comstocker]

Finally making a little more progress

Deck is coming off

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All the plywood is removed, still have to cut off some of the deck screws

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We have furniture! We did end up ordering from PontoonStuff.com

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Taking a break for the week/weekend to get other stuff ready for the cabin. Will get back after it next week putting down the new plywood!

[curtiscapk]

Nice work!

I hope you used the discount code?!!

[Comstocker]

Finally got the 'toon back from the family welder. What should have been a one day job, turned into three weeks thanks to weather and other factors.

Started laying down the marine plywood last evening, hope to get time to get it all screwed down on Wednesday evening. Then on to carpet and railings!

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[curtiscapk]

YEEEEEEEEEEEEEEEEEEEEEESSSSSSSSSSSSSSSSSSSSS! I love to see rebuilds!

[redbeard]

Looking good keep up the good work.

[Comstocker]

Got the marine plywood all screwed down

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A heat gun and some mineral spirits made quick work of the old gate decals

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And one of the new decals installed, yeah the blue finally matches!

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Tonight will be gluing down and rolling out the carpet!