Ozark Deck Boat rebuild

[grillinmike]

I just started an Ozark Deck Boat rebuild project. I am stuck because I am unable to remove the screws that fasten the console to the deck. They all just spin in place. So, I am wondering if I have to remove the whole deck just to get to the nuts if that is how it is fastened. Any ideas besides cutting the screws off or removing the whole deck?

[HandymanHerb]

So does it have skin under the deck, if not you should be able to get to all the screws

[margaritaman]

Can you show us a picture of what you are trying to do?

[Heatman]

If they are stripped you may try to get a flat screwdriver under the head of the screw and try to pry up a bit as you are screwing. I do this alot on stripped out screws in sheet metal. Sometimes just prying up a bit the screw will finally catch and and come out.

Put screwdriver under head of screw, twist screwdriver so one side presses down on the deck and other end presses up on screw. Good luck with it!

[grillinmike]

So I talked to a buddy who has rebuilt many boats and he said that the console is bolted down with the nuts underneath. Figures, never easy fixing stuff. "It's always something"! Anyway, thanks for the tip to look under the lip for the deck screws. Sometimes the easiest thing is staring you right in the face! Thanks again. Here are some photo's of the boat before and some of the tear down. A buddy of mine sold me this for $600 bucks! With trailer! It has an older yamaha 115 that has awesome compression - all cylinders are greater than 130 psi!!! The mechanic was surprised they were all that good. However, the lower unit has a big chunk missing near the propeller so we need a new lower unit. I am in Merritt Island FL. so if anybody knows of somebody selling a lower unit, drop me a note! Today I removed the furniture and the front railings, and half of the carpet. The deck is in great shape except around the gas filler box on the bow and right at the tip of the bow. Kind of looks like dry rot. I may have to fiberglass it or replace the front deck all together. Any suggestions would be appreciated.

[grillinmike]

You can sort of see the screws I was talking about on the console. I think I am going to repaint the console and put new gauges and switches on it and add a new stereo too and a marine radio. The seats are off to the upholstery shop since they were all cracked and brittle from being in the sun. I don't have a roof to put the boat under so what works best, a boat cover or a portable car port?

[rcl700]

Pry the consoll up with a flat head and cut the bolts with a saw zaw. You will be good to go.

Good luck on the rebuild!!

[grillinmike]

OK, so today before it started raining, I was able to finish taking off the console and ripped up the carpet. I decided to just drill the heads off of the screws The wood decking is in great shape and none of it needs replacing. So, after I am done sanding the deck, we are going to put a coat of resin on top, then put down the carpet. We figured we didn't need to take off the rear seat assembly since the wood is all good and nobody sees the carpet under there anyway. So, here are the photos of the deck. I can't wait to get the new carpet on next weekend. Until then, I am going to buff the hull and console and wax the heck out of it to make it shine. Do you guys think I should use that AC coil stuff to polish up the rails?

[grillinmike]

Finally stripped down

[grillinmike]

I cut the carpet right up to the base of the rear seat. This way, when we go to re - carpet the deck, all we have to do is tuck it under the base and it will look good. The only thing is the little bit of carpet strip you see next to the seat base. I was thinking of just leaving it as is, but we will see.

[grillinmike]

I am going to buff out the console and make it shine too!

[grillinmike]

This is just another view of the deck stripped of all the nasty carpet. Looks better already! We are going to put a coat of resin on the top to preserve the deck.

[grillinmike]

My buddy is going to fiberglass the first couple of feet of the bow to fill in some of the dry rot near the gas cap assembly. When we put it all back together, we are going to seal that up better so no water can enter the hull from the assembly.

[grillinmike]

So I may have found a lower unit for the engine! A guy down the road from me has a 1994 yamaha 115 from a boat he is selling. It's locked up but that's ok. I figure for 300 bucks we get a lower unit (which costs anywhere from 600 to 1500 bucks) and spare engine parts when ours breaks down (which hopefully won't happen, but you never know). I am hoping the lower unit fits on our 1991 yamaha 115. A buddy told me that there is a 10 year window so it should bolt right on. Any thoughts???

[BrianP]

I can't help with your question about the lower unit, but this looks like a great project. First, good luck! Second, take pictures as you go through and let us know how it is going.