Transom and floor board repair
The first order of business was to completely strip the boat to the bar hull. This actually only took one day. There is not much to smaller ski boats. The part known as the "cap" is one piece and is pretty heavy. It must be lifted off completely and set aside. The first two pictures show the transom area and floor board after cutting and chopping the old stuff out.
Old stuff chopped out
transom sanded with 60 grit New
transom made from two 1/2"
CDX grade plywood sheets that were
laminated together using fiberglass
resin. A template was made using
cardboard from the outside.
New transom clamped while resin cures Fiberglass cloth laid out
Transom and new floorboard completely covered in fiberglass wet with resin.
Edge view of the completed transom installation with the laminated plywood transom wood cured against the outer fiberglass hull.
Outer Hull repairs
There is one thing I know now about gelcoat is that it is a pain in the ass to work with! Being the extreme do-it-yourselfer that I am (my father is honorably mentioned here...skeptical about the success of this project in the beginning - just kidding dad), I decided to gelcoat this thing myself. After three coats, we finally achieved pretty good coverage and starting the wet-sanding process after it cured.
Final sanding before gelcoat Just after the last coat was sprayed
We went with white because it is the least expensive color and it looks good on the water
