restoring a 2000 ci

[shavertige]

hey all, coming for cali is a restoration on a pretty new boat, a 2000 20ci, i am doing this for all of the people that have wondered what a newer boat looks like torn down, and the engine and everything. this boat was formally a boat used in a summer camp for approx. 4 sesons, the boat seemd to be running bad and started to overheat, so they pulled it out of the water and decided to sell it cheap. that where i came in, we recently picked up the boat about 2 weeks ago and started to go to work, the engine had roughly 2500 hrs. and the interrior was pretty therashed, the engine was belived to have a blown head gasket and would only fine on 4 cyl.'s. the floor board seemd loose/shatterd, the carpet was pretty worn, but the thing had alot of gooddies, everything was stock and coming from a sailing family but having alot of mechanic backround i jumped head first into the project.

hear is a pic of the boat when i first picked it up:
boat outside first day

pic of interrior

anouther interrior pic

resoring is in next post

[shavertige]

Restoration:
so i pull the engine apart, looking very clean but knowing that i will have to pull the heads off, if any one has done this, they will know it is not a simple task on a marine 350, pretty much everything must come off the top side must go, so i went to work, took me a good 4 hrs to do it right by lableing and everything, finnaly i get down to the heads, and shure enough the head gasket was blown threw between the 2 middle cyln., the same thing happend to the other side, my belife is that the boat has seen salt water and was never properly cleaned. now you can see the piston heads when i first took them off
piston heads dirty

as you can see ther was water and some burning but the head valves seem fine, after 2 hrs of elbow grease, wd40, scotch bright and a wire brush i was able to get them to look like this:
clean pistons

now right now i am waiting for new gaskets and will update on engine rebuild, now i will move on to interrior.

[shavertige]

interrior:
from day 1 when i got this the interrior has been pretty therashed, but i took all of the panels off and sent them to an upolster. the eta is 2 week on them and i will keep you guy posted on them. but the floor boards is what shocked me the most, when i pulled the carpet i didnt know it was this bad. when the carpet was on it the was a 1x1' patch that was soft. when i pulled the carpet thease boads were shatterd,the patch is about 2x3' insted of the 1x1 foot patch that i was expecting, heas some pics of the patch and the floor boards
floor boards

there is a forward floor boad not there, the on directly in front of the engine, it was so badly cracked i and totaly refiberglassing it so i pulled it out, for the piece you see, i amm going to grind it flat and refiberglass it.
cracked portion

that is all for right now, all the parts should be hear next mon. and the upolstery should be done in 2 and a half weeks, any questions or comment are welcome, thanks

[bfrank]

Man this is cool, cant wait for the next installment!!!!

[smendez]

That's pretty amazing. You're quite handy. I bet that boat will turn out nice.

I also like the house / cabin in the background in the first picture. It seems like a really cool setting.

[shavertige]

thanks for the nice comments, i got to grinding the old fiberglass off today and put on 2 part penitrating epoxy, after routering off the old surfice, thugh the weather is getting cold, im still hard at work. also, i got a call today that the head were not cracked so i just surficed them, ground the valves, and put in new valve gides. i went the extra mile on the valves for doing the right thing. i have ordered new water pump, thermoustat, and gaskets all around. note: the water pum is idenicle to a car 5.7 L 350 chev. even though the mercury said that to only use there parts, go figure. merc:$180 chevy part: $80, total savings approx: $100
hear are som pic of the after routing:
after routing

my buddy came up and helped me out, 2 people work faster than 1:
my friend

After cutting off fiberglass i iched all over for about 2 hrs, after 3 showers i almost am ichless.

[TeamAllen]

It's great to have your friend helping you out! It looks like dirty work. Your going to owe your friend a few ski runs. Thanks for sharing and keep them coming.

[shavertige]

hears some pics of the floor hardening(the wet looking spots)

epoxy job 1

epoxy job 2

epocy job 3

[shavertige]

UPDATE

got the engine back together today (heads, manifold) went quite easly, heads that came back from the machine shop look great, but they are gray(going to repaint). You will also see that the floors are compleatly fiberglassed and are now rock solid, i also fiberglassed the stringers for some extra help. The boat looks great, upolstry should be hear in 1 to two weeks, the guy is taking a little more time but should look great! Stereo should be pretty kick butt too, doul 10" bandpass subs, 4 3 way pioneer 6 1/2, pyle 1000 watt amp, boss receaver due thurs. hear are some recent pics:

heads and manifold on engine
head
anouther head and manifold on motor
glassed floor 1
glassed 2
glassed 3

[Matt Garcia]

Good job and thanks for posting your restoration process on here.

[raythompson]

As a comedian from the long gone "Laugh In" show would say...


vveerrryy interesting.

[delongheavyhaul]

cant wait to see the finished project. im sure it will be nicer than it was when it was new!

[shavertige]

hears a pic of the stereo i just got, just came in the mail. 4 3way pioneer 6 1/2", pyrimid doul 10" banpass, Pyle 1000watt amp, Boss receaver, Rockford 4gage wire kit.

Stereo

[shavertige]

ENGINE REBUILT!!!

Sorry for the wait, i have had my hands full as you can see... I got the engine back together with all new/ rebuilt parts, strated her up for about 10 seconts with the belt off and got her running sonded great!!! the timing seemd pretty close and everything was going well till yesterday...

pics of the engine rebuilt:

engine rebuilt

pic 2

[shavertige]

Sunday the 25th

sunday put a kink in my hose, i get ready to put the boat into the water for the first time i have had it, ive got plugs, ropes, life jackets, band-aids and a fire extingisher all ready to go. i put her in the water goes in perfetley, in checking for leaks and every thing looks good untill i look at the exhaust mufflers ner the stern. ther are 2 holes in ther squirting out water like a gunshot in a cowboy in a B movie. at first it was only the port side, thin about a minute later somthing really bad happens, the crese where the muffler and the fiberglass elbow seal let go let a load of water come in like a broken dam "AHHH!" i have my digital camera in my hand to take some pride photos for the buddys and end up getting a few panic photos insted. I yell " Get the trailer honey! Fast!" she gets it and i push the boat on the trailer. exciting, so now i have enderd up putting arount 500 buxs in a new muffler syster, hopfully without the leaks... here are some pics:

Leaks

leaks 2