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TOPIC: 1977 Saratoga SunbridgeTOTAL rebuild

1977 Saratoga SunbridgeTOTAL rebuild 07 Jul 2015 10:39 #26

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Along with the Coal tar epoxy, more supplies were needed. Another 6 1/2 gallons of mediium epoxy, 25 yards of 17oz biax, and 40 cubic feet of 2 LB foam mix.

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The original tank sat on an unsupported sheet of plywood. This had rotted out . My plan was to build the replacement with supports.The tank filled must be somewhere close to 700LBS. A little extra support cant hurt. First up was replacing the uncoated ply on the hull with fresh ply and 2 layers of biax.

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Five supports with limber holes were epoxied in place. Then a 3/4" ply deck was placed on top. That got two layers of biax. Holes were also added to it for drainage.

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Getting the tank into the boat was going to be a problem. I got the old one out on my own. The new one takes two people to move. I ended up building a 4' high platform so the tank could be wrestled aboard.

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All I had to do was wait until the girlfriend and her BFF came home from the casino and we should be able to get the job done. Sure enough they came home in good spirits. I conned them in to helping and soon enough it was dropped in place!

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On the last picture there is a white PVC plug cap sticking out of the plywood end cap. This is a drain that was added from the tank bilge area.
I have not covered the stringer installation yet. They are in place. That will be covered as the "risers" that the deck will sit on get installed.
This thread is now caught up to real time. From August 2012 to July 2015. Float-able by fall 2016 wold be nice, but there is still tons of stuff to do. Engine, outdrive, wiring, galley, head, electronics, seats, foam, and lot more wood and epoxy work.

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1977 Saratoga Sunbridge 2550. A project that's coming together here- www.baylinerownersclub.org/index.php/for...nbridgetotal-rebuild

1977 Saratoga SunbridgeTOTAL rebuild 07 Jul 2015 11:53 #27

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I am a lot like you TommyT, I tend to do it myself. Well, I always do it myself. Looks to me like you will have a good boat when your done. I know it's a lot of work and money but I bet the work you are doing is of much better quality than what that boat got brand new from the factory. My boat project isn't as big as yours, new engine so far, and mine should be in the water in a couple weeks but I like what your doing. You just have to keep your boat and enjoy it for years to come when finished.

Another advantage to doing it the way you are. In the future you will know every bolt, piece of wood, wire and parts in the entire boat. You will always know just how your boat is performing and you will know if something needs attention before it quits working. I am looking forward to seeing the finished product.

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1977 Saratoga SunbridgeTOTAL rebuild 26 Sep 2015 06:37 #28

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I haven't posted any updates on this project since July. I have been putting in time on it when I can. 2 weeks worth of "vacation" time spent working on this that just ended and I'm back at the job that pays the bills...
Chapter 8 Vacationing on a boat
There isn't much to say about installing the stringers. The inners were 2x6 and the outers were 2x4. I couldn't find 2x4's over 10' long that were not warped in one way or another. I had to take shorter boards and scarf them together with epoxy. The 2x6's were straight enough from the lumber yard. This is one of the 2x6's drying after a coat of epoxy.

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Once the stringers were epoxied in place I started building up the Plywood boxing that supports the decking. I'm using 5/8" ABX ply for this and the decking.

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This is what it looked like before..

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This is how it sits with the new ply. I added a bit more ply support lengthwise..

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The fuel tank has been foamed in on the sides with 4LB foam. It's sitting on neoprene pads on the top, bottom and ends. I couldn't come up with a way to do that on the sides. The stringers are angled in heading forward. I used 2LB foam to fill all the other spots.

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The last thing I was able to get done before vacation ended was getting the deck ply installed.

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Overall I'm happy to get this far. Well except the gap you can see in the center of the picture. That was one of the first pieces put in when the tank was being set up. It came up a bit short and on an angle. That will get taken care of in the future when the galley head and V-berth get built.
It's good to be back at work. I don't think my knees could take much more of this "vacationing on a boat". -Tom.

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1977 Saratoga Sunbridge 2550. A project that's coming together here- www.baylinerownersclub.org/index.php/for...nbridgetotal-rebuild

1977 Saratoga SunbridgeTOTAL rebuild 26 Sep 2015 11:36 #29

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Wow! My favorite part of BOC is reading the stories of how members brought a boat back from the dead. More power to you Tommy. I see so many abandoned boats sitting in marina storage lots waiting for someone like you to come along.

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1977 Saratoga SunbridgeTOTAL rebuild 25 Oct 2015 21:32 #30

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I'll second that. Glad to see she is coming along. Just finished pulling out the wood on my transom so it will be a while before I see mine matching yours in progress.

Are you still planning on not finishing out the cabin area?

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1977 Saratoga SunbridgeTOTAL rebuild 26 Oct 2015 03:51 #31

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The latest plan is to finish out the cabin area. At least the basics.I have done a few things since the last post. I've got two layers of biaxial cloth covering the plywood that's pictured above. I've also started prepping the area around the forward bilge and V-berth.
My plan, is to make a longer (fore to aft) version of the wedge galley. I'm going to shorten up the V-berth to make room for that. The V will be big enough to Hold the water tank in it and provide a step up through the forward hatch. I want to Make the head area longer and fit a Sealand Traveler 711-M28 head. The original head area was like a phone booth. The Forward tip of the V-berth will be taken up by an enlarged chain locker.
Here are a few pictures from the day I bought the boat-

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This is looking down on the V berth with the galley on the left and the head's forward bulkhead on the right.

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This is the wedge galley. I'd like to lengthen the galley by removing the seat just forward of it .

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This is the fit with the old porta potty. I'll remove the seat area forward of the bulkhead. With the new marine head facing forward, I'll put the bulkhead where the door used to be. Entry to the head will be stepping in from the forward area. that should give pletny of room to "relax".

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This last shot is the original chain locker. I want something bigger to hold 300' of anchor rode. I also want to add drainage for this and the fresh water pump/ tank area.
-Tom.

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1977 Saratoga SunbridgeTOTAL rebuild 05 Nov 2015 00:43 #32

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So how much did that tank set you back and who did the work?

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1977 Saratoga SunbridgeTOTAL rebuild 05 Nov 2015 04:24 #33

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American Tanks www.americantanks.net/index.php made the tank. The price was-
94 gallon tank $1100.
Shipping from southern California to Vallejo CA. $250.
$118. tax.
Total $1468.
These guys got good reviews. They used thicker aluminum than the other companies I got quotes from. .125" thickness versus the stock .080" I believe.
There was also coastlinemarinetanks.com/ out of Washington with good reviews that could have saved on the taxes that California adds. They had a month or so backlog, so I went with American. -Tom.

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1977 Saratoga SunbridgeTOTAL rebuild 05 Nov 2015 04:56 #34

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Man the BOC is a hangout for lunatics, and masochists. Half of us are blowing our spare time and money, on things that should have been fixed with a 1/2 gallon of gas and a match. :woohoo: But the feeling of accomplishment is irreplaceable. Plus boats are chic magnets! Looking good! Keep at it.

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1986 Bayliner Contessa 2850
On the hard undergoing, a full on refit and repower, with Chevrolet 454
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1977 Saratoga SunbridgeTOTAL rebuild 05 Nov 2015 05:45 #35

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Every time I read through your build, I come away feeling that I'm slacking and need to get something done on mine. Thanks for the motivation! The 3 foot difference between the Contessa and the Saratoga is a whole lot more than what it sounds like. Your doing great work on a great BIG boat. -Tom.
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1977 Saratoga Sunbridge 2550. A project that's coming together here- www.baylinerownersclub.org/index.php/for...nbridgetotal-rebuild

1977 Saratoga SunbridgeTOTAL rebuild 06 Nov 2015 18:06 #36

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I think any boat project beyond washing and waxing, gets out of hand. It is always more time , money and parts than what double your original estimate was. It's whether you get done, or give up that separates the crazies from the sane. Plainly I am in need of extensive therapy, although I doubt that would help, I'm too far gone.......

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1986 Bayliner Contessa 2850
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1977 Saratoga SunbridgeTOTAL rebuild 08 Nov 2015 02:36 #37

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" It is always more time , money and parts than what double your original estimate was."
You got that right! The time involved has been MUCH more than I would have ever thought. It ended up taking on a life of it's own. Weekends and vacation time are mostly boat time. The satisfaction of getting things built is awesome. The demolition was dirty work. Once that was done, the project became much more enjoyable.
Money- I've have a spreadsheet for boat building expenses. It can be shocking when it's all added up. So far I've spent $2985.93 in epoxy, bi-axial cloth, flotation foam, Cabosil and misc. resin cups and tubs. $603. in plywood. That's not that much. I'm not ready to confess the total yet. Besides that number is going to jump up soon. Michigan Motorz will need $8k for a complete engine. I would like to see this thing finished for about $25k, sitting in the slip ready to rock. All it needs is a little more time and money. -Tom.

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1977 Saratoga SunbridgeTOTAL rebuild 09 Nov 2015 21:56 #38

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TommyT wrote: You are right. Rebuilding a boat is a losing proposition. Rebuilding costs more than the boat will ever be worth. If I would have bought a turn key boat, I could have had years of fun on it already. That all makes sense. doityourselfer, your name says it all. I like to do it myself and learn along the way. I've never been married or had any kids, so tossing cash around on money pits won't get me in anyone's dog house. Previous money pits include the junk car from pick n pull I drove home for a few hundred.


Add in a few wheel barrows of cash and a few years of labor and it ended up as this. Drag racing can make boating seem like an inexpensive hobby.

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Then there was the motorcycle phase. Got this off of Craigslist for a few hundred. It came with the exhaust cam peaking out of the valve cover.

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Add in more cash and time than it will ever be worth, and you get this.

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I guess the point to all this is.. that this isn't about trying to get a big boat on the cheap. It's about doing it yourself. Knowing every system. Every part of the boat. To be able to say "I did it". Not having to take things to "my engine guy" or "my fiberglass guy". The only thing that I don't like about having a long term project is everyone at work that keeps asking when it will be done. It will get done when it gets done.
One last thing on the "keep it or toss it" subject. I'm past the point of scrapping it. The gas tank has already been made and that cost almost as much as the boat! When I get this thread up to date, I'll post the total cost so far. If this tub gets done for under $17k I'll be shocked and happy! -Tom


Temporary hijack...is that a 1968 Dart?
I had a 1968 Dart GT convertible in the 90's that I bought for $1,800 and sold for $3,000 a few years later...before classic cars sky rocketed.
I also have a KLR650, that was green...till I dumped thousands into it with composite fairings and such...hence my name from the KLR forums, Green650.
Keep up the good work.

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1977 Saratoga SunbridgeTOTAL rebuild 09 Nov 2015 22:57 #39

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I figure when all is said and done 25 K will be about right. I'm well over 3k in glass epoxy and other construction materials. Add in another 1500 soon for gastank. Then the reall money spending starts.

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1986 Bayliner Contessa 2850
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baylinerownersclub.org/index.php/forum/g...to-leak?limitstart=0

1977 Saratoga SunbridgeTOTAL rebuild 10 Nov 2015 16:18 #40

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That's cool Green650! That is a 68 Dart. I'm T748 on the KLR forums. Did you come down to the big KLR tech day in Northern California a few years ago? Is this your bike? -Tom.

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1977 Saratoga Sunbridge 2550. A project that's coming together here- www.baylinerownersclub.org/index.php/for...nbridgetotal-rebuild

1977 Saratoga SunbridgeTOTAL rebuild 26 Nov 2015 21:51 #41

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Winter has come to Northern California. 50 degree days and nights dipping into the high 30's. Not winter like the folks in snow country get, but still too cold for foam and epoxy work. I've got a setup to work around that. I should be able to continue work through the season. I bought one of those oil filled room heaters that looks like the radiators found in old homes. That and a few well placed moving blankets gets the interior temperature up to 80 degrees when it's 50 outside. Perfect temperature for foaming. With that toasy temperature, Iv'e put down two layers of biaxial cloth on the deck. I've also added another section of decking up to the forward bilge. I'd love to work on that right now, but I've been banned from boat work on Thanksgiving.

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Looking ahead ,the V- berth and forward bilge are the next things to be built. The V will be a foot or so shorter for more walking room. The new wood is setting where I think the new V will be placed. -Tom.

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1977 Saratoga SunbridgeTOTAL rebuild 27 Nov 2015 18:41 #42

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TommyT wrote: That's cool Green650! That is a 68 Dart. I'm T748 on the KLR forums. Did you come down to the big KLR tech day in Northern California a few years ago? Is this your bike? -Tom.


My KLR is all black now. I do have that twin light fiberglass fairing though, except without the beak.
I can't remember the maker though, it was from BC. Funny, I ordered it from Canada when I was down in AZ. Now it almost made its way back home.

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1977 Saratoga SunbridgeTOTAL rebuild 11 Jan 2016 23:07 #43

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Ok. I'm happy now. I'm not alone.
I picked up a 1974 Saratoga Command Bridge that just needed a basic cosmetic refurb........., WRONG!!!
The more I strip out to replace the more problems I find. It would appear this will also be a total rebuild :(
I'm not sure if my skill level is up to it, but finding this thread and the BOC group has lifted my spirits a little.
Thanks for sharing Tommy T, and I'm sure ill be soliciting advice from all of you shorty

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1977 Saratoga SunbridgeTOTAL rebuild 12 Jan 2016 00:50 #44

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Wow.

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Phil, Vicky, Ashleigh & Sydney
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1977 Saratoga SunbridgeTOTAL rebuild 12 Jan 2016 16:18 #45

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WoW!
This project has been going on a lot faster than others... Nice work.

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1977 Saratoga SunbridgeTOTAL rebuild 12 Jan 2016 16:52 #46

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Ruffryder wrote: WoW!
This project has been going on a lot faster than others... Nice work.

Op stated the project started in 2012 :whistle: no such thing as fast when it comes to major fiberglass repair :lol:

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1977 Saratoga SunbridgeTOTAL rebuild 12 Jan 2016 17:21 #47

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Dave, I usually just go through the pics.
I looked at the date when this thread started.... perhaps it's another 4 yr project :whistle:

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1977 Saratoga SunbridgeTOTAL rebuild 13 Jan 2016 18:58 #48

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dillmargy wrote: Ok. I'm happy now. I'm not alone.
I picked up a 1974 Saratoga Command Bridge that just needed a basic cosmetic refurb........., WRONG!!!
The more I strip out to replace the more problems I find. It would appear this will also be a total rebuild :(
I'm not sure if my skill level is up to it, but finding this thread and the BOC group has lifted my spirits a little.
Thanks for sharing Tommy T, and I'm sure ill be soliciting advice from all of you shorty


Don't question your skill level, you have it. The only skill needed to start a rebuild is the "Internet search" skill. I came into this having never worked with fiberglass. The only boats I've owned were aluminum, with the big boat being a 14 footer. Reading a lot of internet posts and product literature has helped a bunch. Another thing that's helped me, is to focus on each step instead of looking at the whole project. Looking at the whole thing, it's too easy to get overwhelmed. Only look at the big picture after you've completed a step. Then it doesn't seem so big! Start a post on your boat and show us plenty of pictures. I'd love to see what the layout of the interior is. What engine/ drive does it have? -Tom

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1977 Saratoga Sunbridge 2550. A project that's coming together here- www.baylinerownersclub.org/index.php/for...nbridgetotal-rebuild

1977 Saratoga SunbridgeTOTAL rebuild 13 Jan 2016 19:22 #49

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Ruffryder wrote: Dave, I usually just go through the pics.
I looked at the date when this thread started.... perhaps it's another 4 yr project :whistle:

4 years might be a bit optimistic. 5 sounds more like it. Besides getting the fiberglass decking done, it's going to need:
Complete wiring 110v and all 12 systems.
Plumbing. Fresh and black.
Seating, a galley and all the other comforts of home.
Install a complete engine package. $$$
Out drive rebuild and installation.
Trim tab installation.
Trailer rebuild (Brakes, tires and lights).
Dash, gauges and electronics.
And much more...
Man, looking at all that, it's overwhelming! :ohmy:
-Tom.

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1977 Saratoga SunbridgeTOTAL rebuild 13 Jan 2016 19:48 #50

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This project has changed directions due to "El Nino". It's raining just about every day. Fiberglass and wood work will have to wait. I've moved over to the garage to start the outdrive project. The goal-
Start with an corroded old 70's Volvo Penta 280 outdrive. With the wonders of Ebay and Craigslist, Frankenstein together a more modern 280 Duo Prop.
I'll start a new topic for this build up soon. -Tom

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