More repairs....I'm about at my breaking point!

[BlewByYou88]

Now I'm questioning Sea Rays quality and engineering..... 268's Beware! I noticed this last season that there was a slight divot in my bow about half way down that extends from one side of the Bow to the other. Everytime someone walked across this point, it would bow terribly. Well, it started showing stress cracks in the gelcoat, so now I'm worried about the glass... Just a weak spot or???? Well, as luck would have it, it would appear that the soft spot is directly over the cross beam in the cabin where the curtains attatch. Strange right? I would have thought that would be a strong point since there are wooden cross beams glassed in under the deck....CAN YOU GUESS WHAT SEA RAY DID?

I pulled down the headliner and everything looked fine....I relaized the deck had a Balsa Wood core....ok so the only way to find out more would be to bust out the first layer of glass on the underside of the deck, and chop out the balsa...or go through the top and tear up gelcaot and non skid....I decided on going in from underneath the deck.

So, I thought, might as well bust out the cross members first, as I will probably have to put up new wood and re-glass anyway. Upon busting out the cross members, I found Sea Rays Fatal flaw in the Bow, and what caused the soft spot. There was no coring or second layer of glass under the cross members....in fact the glass is thin...scary thin...I can push with one finger and barley any pressure and make the deck flex up and down....

Attached are the pics of my reign of frustration on the bottom side of the deck....I don't have the pics of the low spots on the bow.

I cut out a 1.5' section the whole way across the underside of the deck. My plan is to take a piece of Oak or Maple and coat it with resin, and use a jack to push it securly up into the deck structure. This should make it far stronger in this area and act as a more stable filler than the Balsa Core. Then reglass all exposed areas with some Woven glass for the second layer. I will keep you guys posted as I progress.

If you guys see anythign strange or have better ideas...please feel free to chime in!

:smt101

 

[sdarc]

Sorry to hear about this, If you use oak, use white oak instead of red. White is not porous red is.

And Bruswick obtained both Sea Ray and Bayliner in 1986... Hmmm!

 

[Henry Boyd]

I understand your being upset, but it is a 24 year old boat. Call me crazy, but it seems to me that a problem that takes 24 years to surface is hardly an engineering flaw.

I think using oak might be too stiff and create its own set of problems. Oak also has a tendency to warp at the slightest bit of moisture. Using marine plywood instead would provide the strength.

Henry

 

[KC_Sundancer]

I understand your being upset, but it is a 24 year old boat. Call me crazy, but it seems to me that a problem that takes 24 years to surface is hardly an engineering flaw.

Henry

Definitely an engineering flaw and weak point right from the start. A clear line for the deck to be able to "fold" along.
+1 on the marine grade plywood - more stable.

 

[alwhite00]

Man, I know it might not be right but if that's the worst of it - After nearly a quarter of a century I would say they still built a pretty nice boat.

LK

 

[BlewByYou88]

Bear in mind getlemen, shes a 24 yo boat that on a good day looks like she just floated in off the line. This boat hasn't had any abuse or neglect in that area...Shes always been under cover and shes a trailer queen...Its a clear flaw, you don't put an 1/8" of Glass over a high traffic area without ample support from underneath.

 

[Pyrojodge]

Geese, Stace good luck buddy. I agree on the marine lumber rather then a solid piece of wood. The engineered wood will not "move" like a solid piece. Good luck with the repair. Just think you will have a brand new boat that is engineered better then when it came off the line when you are finished!

PS: I am also jealous you're still able to boat! :smt089

 

[CV-23]

He's just gearing up for those pole dance girls on the bow! Just kidding......maybe?.....Mike.

 

[Buckeye Boater]

Stace,

Do you think the damage may be the result of all those young ladies dancing on the bow during the bachelor party last month? Good thing they didn't fall through the deck!!! By the way, we're still waiting on those pictures!! :grin:

 

[OldSkool]

Got to admire a guy who works resin and fiberglass overhead. Sounds like she will be in better shape than new. Go with the plywood as a more stable material. Keep the pictures coming so we can see your progress.
Best of luck.

 

[BlewByYou88]

Stace,

Do you think the damage may be the result of all those young ladies dancing on the bow during the bachelor party last month? Good thing they didn't fall through the deck!!! By the way, we're still waiting on those pictures!! :grin:

Geez, I forgot about those, I will get them up shortly....Can't do all of them as some are not appropriate for this paticular site.

 

[dicor]

I'm hoping to hear from another 1988 268 owner to see if they have the same issue. Curious as to whether it was a mistake during the build or designed this way.

 

[BlewByYou88]

Talked to my local MM today...They have never heard of this issue, but they agree that this was a factory flaw when she was built. They were actually quite shocked when I showed them the pics. My cruiser was built here at the Phoenix, AZ plant back in the day when they were still open, they closed it back in the mid 90's. They were also curious was it just my boat, 268's in general, or just a Phoenix Plant f* Up.

Anyway, starting the repair process, got the first piece of core resined up into place, and the divot in the bow is gone, but that could just be because I have a jack holding up the support right now.

 

[BlewByYou88]

The final outcome...Looks kinda crappy, but the headliner will take care of it. BTW....Overhead Glass work SUCKS! This has been without a doubt one of the $****tiest projects I have ever undertaken...Its definatley an art,skill, and job I would never want to have, but I did learn alot...

 

[Big Island Lifer]

Nice work!


Sent from my iPhone using Tapatalk

 

[Pyrojodge]

Looks great pal!

 

[BlewByYou88]

The final outcome, what do you guys think? Does it look like I just made a $500 deck repair? It would have only been $400, but I messed up one of my batches of Resin/Epoxy....it was not a pretty site.

 

[Big Island Lifer]

Looks like your boat is a lot better off!

Great work.


Sent from my iPhone using Tapatalk

 

[BlewByYou88]

Just as an added bonus...for all of you who are laid up already.....I will be spending this glorious weekend out on the lake with a lady friend! Estimated to be in the 80's through the weekend.....

 

[mwph]

Stace, When we talked briefly at the Homecoming I thought....That guy is a real hands on boater. Now there is no doubt. Huge project, looks like you handled it well. And quickly too!

Congrats.