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Author Topic: Wakesurf Boat Remodel  (Read 1805 times)

Offline SONIC.

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Wakesurf Boat Remodel
« on: Oct 27, 2017, 17:14:58 »
Once again I'm going to post a completely non motorcycle related project, because, well, I like you guys and I like going back through build threads years down the line.

While I have been very busy not working on any of my motorcycle projects  ::) i picked up another project.
It's a 2001 Tige 23V Wakeboard boat.
I want to turn it into a modern Wakesurfing machine.

It looked in much better shape than it was.

In typical fashion I decided fuck it I'm going to tear it all the way down because I can't help myself.

About a week later I decided to pull the engine as you can see. It needs someTLC, runs great but looks a bit worn, so it will get a freshen up over the winter with powder coated everything.

« Last Edit: Oct 27, 2017, 17:29:16 by SONIC. »

Offline SONIC.

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Re: Wakesurf Boat Remodel
« Reply #1 on: Oct 27, 2017, 17:28:01 »
From there I moved on to the interior.
The tower came off to get some additional bracing, new heim joints, and new powder coat.

The first real order of business was upgrading the floor. This vintage of boat still had carpet floors and wooden decks. So the deck is marine plywood with a layer of fiberglass over the top. Over the years the fiberglass had flaked and popped and was just junk.
I want to go modern with the flooring with means gelcoat and seadek:
Like this:


That means the floor has to be perfectly factory smooth and beautiful. Shit.
There's a few options here, first is to just pull all the glass replace it, and sand it back smooth. This is a LOT of work and would never end up the way I wanted it to. I'm not that patient.
Option 2 is to recover the floor with a fiberglass composite board and then glass on top of that. That's what I did. This gives me a perfectly smooth surface for the final layers of glass making the sanding and fairing that much easier.

Made OSB templates, copied them to the Coosa board and glued them down with Polybond B39, which is like bondo on steroids.




Boom smooth surface for glass.
« Last Edit: Oct 27, 2017, 17:29:56 by SONIC. »

Offline Drewski

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Re: Wakesurf Boat Remodel
« Reply #2 on: Oct 27, 2017, 19:23:17 »
Sweet project Sonic!!  8)  I love your plan.  :D

How was the rest of the structure below the floor? Any stringer damage from water?  :(
The Kawasaki Line-Up:

"Keepin' the Good Times Rolling"

STREET:
'77 "Faux" z1 kz/zx10r "Resto-Mod" BOTM
PLAY:
'72 kv75 "Pitbike" 4 Sale
TRACK:
'81 GPz/kz550 "TrackBike"
ON THE WORK BENCH:
SeaGlider's '71 h1a/750 "FBG Sleeper"
Drewski's '74 h2b Tracy/zrx Project
FOR SALE/GONE:
'05 zx10r "RetroLookRacer"
'02 zrx1200r "DailyRider" SOLD & GONE!!
'99 zrx1100 "euro-style" SOLD & GONE!!
'75 s1-250 Triple "Survivor" SOLD & GONE!!
'74 h2b/FZ "Mongrel" BOTM, SOLD & GONE!!

Offline SONIC.

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Re: Wakesurf Boat Remodel
« Reply #3 on: Oct 27, 2017, 19:29:37 »
Thanks!
Nope stringers are rock solid thankfully.

Offline jag767

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Re: Wakesurf Boat Remodel
« Reply #4 on: Oct 27, 2017, 21:08:45 »
You don't do anything small do you? Lol. So interested to see this done.

Offline Drewski

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Re: Wakesurf Boat Remodel
« Reply #5 on: Oct 28, 2017, 02:04:24 »
Thanks!
Nope stringers are rock solid thankfully.

Nice!   8)

I still hafta get into the Checkmate to see where it's at. I'd LOVE to get the same news.  ;D  I'm not holding my breath though. Older boats generally have lots of wood below the floor. The majority of the time there's at least some rot down there.  :P The joys of owning old boats!!  ;D

Looks like you're off to a great start brother! Carry on Sir!  :D

The Kawasaki Line-Up:

"Keepin' the Good Times Rolling"

STREET:
'77 "Faux" z1 kz/zx10r "Resto-Mod" BOTM
PLAY:
'72 kv75 "Pitbike" 4 Sale
TRACK:
'81 GPz/kz550 "TrackBike"
ON THE WORK BENCH:
SeaGlider's '71 h1a/750 "FBG Sleeper"
Drewski's '74 h2b Tracy/zrx Project
FOR SALE/GONE:
'05 zx10r "RetroLookRacer"
'02 zrx1200r "DailyRider" SOLD & GONE!!
'99 zrx1100 "euro-style" SOLD & GONE!!
'75 s1-250 Triple "Survivor" SOLD & GONE!!
'74 h2b/FZ "Mongrel" BOTM, SOLD & GONE!!

Offline SONIC.

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Re: Wakesurf Boat Remodel
« Reply #6 on: Oct 28, 2017, 12:47:53 »
Thanks!
Tige had a lifetime warranty on their stringers at this time, so they did a really good job of encapsulating them (to cover their ass haha) and used XL Panel which doesn't really rot even when wet.

Before I bought this one I looked at a few older Malibu's and Supras and all of them had mushy rotten stringers. I had to drill holes into some poor guys boat to show him so he would believe me.
All the motor mount lag bolts were spinning in the stringer so I told him the stringers were toast and I'd be looking elsewhere. He was adamant that his mechanic had just inspected them and they were in great shape. I said toss me that drill over there and I'll show you. Bored a 1/2" hole and as soon as I got through the glass it was like drilling into play dough. Needless to say he was not a happy camper.


Offline SONIC.

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Re: Wakesurf Boat Remodel
« Reply #7 on: Oct 28, 2017, 12:57:26 »
Next up was the seating.
The boat originally came with twin captains chairs like this

But the genius that I bought it from "lost" the passenger side. He was using a yeti cooler in it's place, so I worked that into the deal :D

The captains chair was a bit of a novelty (lots of wasted space and lost storage), no one really liked it and it never caught on so all future boats have wrap around seating there, so that's what I'm going to build.

Once again I started with OSB (I have a lot of osb).

Once that fit like I wanted I digitized it and threw it on the CNC to cut from 3/4" Coosa Board.


I cut away a small section for the end to rest on from the existing seating:

And it fits like a glove.


I built the bottom the same way and then tossed a layer of glass mat on the back side for bracing. The front and top will get fiberglass cloth and be blended into the existing seating.


And that's caught up to there it currently sits.
Tons of work to do yet.



Online irk miller

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Re: Wakesurf Boat Remodel
« Reply #8 on: Oct 28, 2017, 15:28:59 »
You're out of your fucking mind.  ;D

Offline SONIC.

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Re: Wakesurf Boat Remodel
« Reply #9 on: Oct 28, 2017, 15:42:21 »
First the wife.
Then the doctor(s)
And now you.