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TOPIC: It's been a year since the gas tank started to leak

It's been a year since the gas tank started to leak 14 Oct 2013 04:00 #26

  • SKUA 28 Contessa
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Epoxied in

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0

It's been a year since the gas tank started to leak 14 Oct 2013 04:01 #27

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Bilge Deck in Progress

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0

It's been a year since the gas tank started to leak 14 Oct 2013 04:02 #28

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Bulkhead

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0

It's been a year since the gas tank started to leak 14 Oct 2013 05:06 #29

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Nice job on the glass work and your boat is going to be a fun ride once more...

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Doug ;}
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"Go Aweigh to" Photos < click on red letters... 2001 Bayliner 2452 w/6.2 HO (paid for)


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It's been a year since the gas tank started to leak 14 Oct 2013 15:18 #30

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Yeah but I've the itch like crazy, and not the boating itch, lol.

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0

It's been a year since the gas tank started to leak 15 Oct 2013 13:47 #31

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First attempt at a plan for the cabin remodel. It's not quite to scale nor are the dimensions quite there, but good for a start. So what do you guys think??

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0
Last Edit: by SKUA 28 Contessa.

It's been a year since the gas tank started to leak 16 Oct 2013 05:05 #32

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Reversed the cabin layout, and a couple of "3D" interior shots.






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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0
Last Edit: by SKUA 28 Contessa.

It's been a year since the gas tank started to leak 16 Oct 2013 12:02 #33

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A lot of people will benefit from your project, and you documenting it well.

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Regards
Whiskywizard
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It's been a year since the gas tank started to leak 19 Oct 2013 23:25 #34

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Glased over the forward tank deck, (waste and flush tanks). Turned my attention to the engine mounts. I jacked up one side with the engine mount adjustment, just enough to sneak a pile of 2x4s under the crank pulleys, and then lowered it back down. I then cut off the entire engine mount down to the hull leaving a slight lip for positioning. Observation : when making the hull , Bayliner once again, split the lamination. 2 or 3 layers of cloth or woven under the blocks, then the rest over the engine stringers, and then onto the hull. I am fabrication the new stringers, and wrapping them in a layer of glass before laying them in. After that I will epoxy them down and tabb them in. I am leaving a 4 inch space between the new engine stringers and the transom, so that I can redo the transom later. The filler block will be epoxied in between the two, then glassed in.

Some pics tomorrow.

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0
Last Edit: by SKUA 28 Contessa.

It's been a year since the gas tank started to leak 23 Oct 2013 03:08 #35

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Sorry about the delay in pictuture posting, My daughter wrecked her car last night.

So here we go, first up is the new tank deck, and starting to lay out walking deck support grid.


The method of holding up the engine to cut the stringer loose


The stringer cut and cleaned out, prepped for new core.


The old waterlogged and rotted stringer split open for post mortem.


New engine stringer cores are currently setting up, before wrapping in glass and epoxy. Then I will lay them into what is left of the original box, and retab. Had to cut a 15 degree wedge to get them level. Will cut out the other stringer when this one is back in. then onto the main stringers.

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0
Last Edit: by SKUA 28 Contessa.

It's been a year since the gas tank started to leak 23 Oct 2013 04:04 #36

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Wow your really going to town on your project. love to see those pics, especially of motor stringer repair as I am doing the same on my new to me 2556 along with a fuel tank replacment.
keep up the good work!.

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It's been a year since the gas tank started to leak 25 Oct 2013 15:37 #37

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Great work. I'm following closely since I'm currently upside down in my 2150, cleaning out rot, removing the gas tank and engine etc. etc.

I believe this type of project to be a kind of madness that no one else on the planet except a boater could possibly understand. My attempts to tell other people about what I'm doing usually produce dead silence and the inevitable "Why not just buy a new one?"

Oh well...I know why I'm doing it and clearly so do you. Best of luck and keep posting. It's a great help.

My '86 Capri 2150 Cuddy resto thread: www.baylinerownersclub.org/index.php/for...2150-cuddy-and-motor

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"I once owned a 6hp British Seagull outboard. It was advertised as the world's most basic and durable motor. I found that to be true. The only moving part was the owner."

It's been a year since the gas tank started to leak 26 Oct 2013 04:41 #38

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I'm rather amazed to see so many other crazy people with nothing else to do!!!

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0

It's been a year since the gas tank started to leak 26 Oct 2013 05:09 #39

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I want to lower the head floor in my 2452 on of these day. At 6'2" I just don't fit.

Nice going

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It's been a year since the gas tank started to leak 04 Nov 2013 05:44 #40

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Latest installment ny renovation.. I continued to layout the support grid for cabin deck, using 2x4 cleats on the top og the stringers. Also reassesed the battery situation and decided to allow for upgrade to 4 GC batteries, by cutting the battery well larger . This removed a fair amount of the bilge deck I had installed, oh well.

I also decided to cut down the starbord side outer stringer to bring it down to the same deck height as the rest. Another revision to the interior layout, allowed this, so now ther will be more open area between the dining table and the storage cabinetry/steps at the rear bulkhed.



Observations today: Funny smell of peanut butter anytime I have cut into the original stringers that are dry and unrotted.
Can't figure that one.

Now I know Bayliners take a bashing for poor quality, lack of this or that, blah,blah ,blah. And the
hull laminate is plainly thinner in some area, than say some other brands. Now that being said,
I can't remember ever hearing about a laminate failure or sinking from "quality" issues. The older
boats have issues with rot in the stringers and deck, but what brand of 20-30 year old boats
doesn't. (Some Searays in this era had balsa cored hulls and DID fail catastrophically.)
Now the question.. If the boats are so "cheap" , crappy and poorly made, why don't they
fold in half and sink, particularly when, rotted out? Well at least in the larger boats, I think this is the
answer. This is the cross section of the 1x8 stringer I just cut out today. You wil notice that the FG
and resin are not far short of an inch thick itself.

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0
Last Edit: by SKUA 28 Contessa.

It's been a year since the gas tank started to leak 04 Nov 2013 05:48 #41

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Alaskanmutt wrote: I want to lower the had floor in my 2452 on of these day. At 6'2" I just don't fit.

Nice going


I'm 6'3" and fit fine... you need a 2001 or newer 2452/242

Nice job on the tank mods...

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Doug ;}
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"Go Aweigh to" Photos < click on red letters... 2001 Bayliner 2452 w/6.2 HO (paid for)


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It's been a year since the gas tank started to leak 14 Nov 2013 04:56 #42

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Well while waiting for a new batch of 24 oz biax, I have finished up the battery box. Also changed the right side stringer and deck height plan again. I don't want to notch the stringer too much for access, for the wires and hoses, so the final plan is too leave the deck at the original stringer height back to 64 inches, then cut it down to the rest of the stringers. This way there will be an aditional three inches for everything to run under. The dining table will fold against the hull here so it wont present any obstructions in the walk way. The stools will lock against the rise, and be held in place by cleats or straps.

New water tankage plan is for a pair of 25-30 gal tanks, placed in the engine room low, against the gunnel, with individual valving to allow for ballasting and trim. This is close to the 30 gal single tank originaly in the engine compartment, but more evenly ditributed. Now all of the heaviest items , fuel, water, batteries, holding tank, are to be below the water line or within 10 inches above. Should improve stability. Seperate starting battery will be located permanently, after boat is returned to service, to allow strategic placement for trim.

Keelson under head was found to be rotted from PO allowing shower to drain into bilge. Not unexpected, as this was the cause for the rotten bilge deck. Found this while starting to cut out the galley decking. Cheap plywood deck was cracked through several knot holes.

Engineering report :

I now have the answer to how thick is the hull. I removed the original seacock, and measured the thickness. It is 3/8 inch thick at this location. And before I added lamination, the hull was less than this, directly under the gas tank, and under the waste tank. So it starts around 3/8 to 1/2 in the bow and keel , then thins down to slightly more than an 1/4 under the cabin floor. As you move toward the stern, the hull increases in thickness to close to an inch at the transom. Hull sides are never more than 1/4 inch except where the factory added tabbing and furring strips to support wiring and structures. The hull sides are quite flimsy without any framing from the furniture. Not sure I would call this cheap or crappy. Yeah it's not Hatteras, but has held up without any issues all these years.

Original plywood used in construction varies from typical BCX in some areas, (furniture, and framing and decking) to what appears to be marine ply, of unbelievably low quality, (decking, furniture), full of voids, delamination, and pieced together. Thicknes varies all over as well, 5/8 and 3/4 used for furniture, cabinetry, something less than 1/2 for decking and framing, and some stuff that looks like 1/2 thick paneling used for the deck frame between the salon and galley!

Pics to follow.

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0

It's been a year since the gas tank started to leak 15 Nov 2013 04:31 #43

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New battery box

New backsplash/ partial bulkhead

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0
Last Edit: by SKUA 28 Contessa.

It's been a year since the gas tank started to leak 26 Nov 2013 04:16 #44

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New engine stringer


Backsplash/frame tabbed in


Populated battery tray


More to come

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0
Last Edit: by SKUA 28 Contessa.

It's been a year since the gas tank started to leak 30 Nov 2013 22:52 #45

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Uh Oh!! While cutting out the old deck by the galley, I stopped to peer under the head, as I needed to repair rot in the keelson and framing for the head and compartment under the vberth. At firs,t I saw what I thought was line of dust, but on closer inspection, it was the first strake in, from the starbboard chine, had cracked through and spalled the inner layer of resin and glass. I then looked on the outside of the hull and sure enough there were radiating cracks in the hull paint in the same area. My guess is that when the hull came down on the hard, after Sandy, it must have settled on a high spot, and flexed too much. Either that, or it's from the recovery effort after.

Currently in the process of remove the head, to gain access to the hull in this area. I plan on back cutting a notch through the crack, filling with fiber reenforced epoxy, then laying a couple of layers of 40oz triax cloth and epoxy over the entire area. This should be more than strong enough a repair. However this was an unanticipated failure. If I hadn't been in the area doing redecking, this would have gone undetected until it got worse, and cracked through from flex. Probably wouldn't have sunk, but would have been leaking, eventually.

Pics of the new developement coming soon.

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0
Last Edit: by SKUA 28 Contessa.

It's been a year since the gas tank started to leak 01 Dec 2013 00:07 #46

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Always something... Hope its not as bad as I am thinking... the fiberglass can be repaired on the outside. I would certainly repair the spidering...

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Doug ;}
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It's been a year since the gas tank started to leak 01 Dec 2013 01:34 #47

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It looks like you're doing a great job. Will you have the height for the head that far forward?

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It's been a year since the gas tank started to leak 01 Dec 2013 05:25 #48

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Keel and framing coming out. rotted


Starting to remove door and frame


Onto the cabinetry


Moving along


Closing in



Down to thehull

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
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It's been a year since the gas tank started to leak 01 Dec 2013 05:33 #49

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Head is out

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It's been a year since the gas tank started to leak 01 Dec 2013 05:35 #50

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Here is the strake. The lower edge is delamed pretty much the whole way. Just spalled off the interior surface a tad. Bonus roofing nail in the laminate. I need to ponder what I'm going to do for a minute.

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
Making real progress now
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