Structural hull damage 2005 SD

BrentJones

BrentJones

Member
Oct 4, 2006
405
Fenton/Lake Ozark, MO
Boat Info
2005 240 Sundeck
Engines
6.2L
So I just had my boat pulled out for drive service, oil change, impellar change and dewinterization and the service techs found major structural damage in the stern of the hull. When the tech pulled the outdrive, he noticed water continually leaking out which raised a read flag. After more investigation, it was discovered that the hull was cracked in several places where it was put together in the factory. Water was able to breach the interior behind the fiberglass and it has destroyed the structural integrity of the stern area. The main service writer has never seen anything like this in his 20 year in the marine industry. The quote to have it fixed was $9,000 to $10,000. It sucks especially since I am in the process of selling.

This is a non-sea ray marina, but I have used them for the last 10 years. They used to be a Formula dealer, but I trust them and they are well respected at my lake. Their warranty person called Sea Ray with my HID# for warranty info and it is not covered. I thought the hull structure had at least a 10 year warranty, but apparently not. I am going to call Marine Max today and start there, but I'm not expecting to have any luck with them. My last hope would be to claim it to insurance.

This boat only has about 275 hours and I never ran it hard, so it is really puzzling that this has happened. Does anyone have any suggestions on how to get this resolved, hopefully with Sea Ray?
 
got any picture of the damage? Having trouble visualizing "cracked in several places where it was put together in the factory" at the stern of the boat...
 
BrentJones said:
Not sure how they got it out. Are you implying that they may have caused the damage?
Click to expand...

I'm not implying anything yet :) Lets diagnose first.

But it is some kind of structural damage in an unusual place. It is in one of the lower corners - so the most obvious would be either issues with the making of the boat - or the boat has had some kind of "impact" while resting on the rear.

Have you ever had problems with water leaking out of the blanking plugs in the engine room? They will usually leave black stripes from the blanking plug and downwards.
 
I've never noticed any leaking at all or any indication of that. I am always suspicious of things that happen to the boat while I'm away. It is also suspicious that the dock had ice damage this winter which also damaged my lift. They just let me know of that damage and that their insurance was covering it. I can't think of anything I would have done to cause the damage. I have never run aground or even run in shallow water. Everywhere I boat is 20-100 feet of water. It is just a weird situation.
 
Well, you have started the process in the wrong way.

There are 2 entities who have any "pull" with Sea Ray: You, as the owner, and the Sea Ray dealer from whom you bought the boat, and ig you have relocated, the Sea Ray dealer who services the boat now. Sea Ray will sometimes cover out of warranty issues of this nature when the local dealer knows the boat and the service and maintenance history can be verified. You also stand a better chance of getting some help if you are the original purchaser and you are the owner of record in Sea ray's warranty files. Sea rya just wants to be sure this isn't a derelict, neglected or abused boat. An independant marina, not affiliated with Sea Ray who used to be a Formula dealer has no standing and will get a by t he numbers answer, as you discovered.

If you have now taken the boat to a Sea Ray dealer and can get them to be your advocate with Sea ray Customer Service, you stand a change of getting some help. If the dealer comes back with a "no".......if it is a Marine Max outlet, most of their stores don't want to get involved in resolving this type problem...they are managed by the numbers and there will be no profit in this one........then you should call Sea Ray Customer Service yourself and calmly explain that you bought a sea ray based on their reputation for quality and value and that you are very disappointed in your boat and would like to be sure they are aware of your situation and ask for their help in reaching a solution. Be positive, be professional, do not threaten.....just explain your disappointment in your Sea Ray.

Good luck with it.............


Also, the photos are not viewable from the link you posted.
 
Last edited:
fwebster said:
Well, you have started the process in the wrong way.
Also, the photos are not viewable from the link you posted.
Click to expand...

Here's the photo's...
Crack 1.jpg
Crack 2.jpg
 
What is the "skinned up" area on the chine to the right of the water leaking out?

Has this boat been in the water all winter?
 
BrentJones said:
So I just had my boat pulled out for drive service, oil change, impellar change and dewinterization and the service techs found major structural damage in the stern of the hull. When the tech pulled the outdrive, he noticed water continually leaking out which raised a read flag. After more investigation, it was discovered that the hull was cracked in several places where it was put together in the factory. Water was able to breach the interior behind the fiberglass and it has destroyed the structural integrity of the stern area. The main service writer has never seen anything like this in his 20 year in the marine industry. The quote to have it fixed was $9,000 to $10,000. It sucks especially since I am in the process of selling.

This is a non-sea ray marina, but I have used them for the last 10 years. They used to be a Formula dealer, but I trust them and they are well respected at my lake. Their warranty person called Sea Ray with my HID# for warranty info and it is not covered. I thought the hull structure had at least a 10 year warranty, but apparently not. I am going to call Marine Max today and start there, but I'm not expecting to have any luck with them. My last hope would be to claim it to insurance.

This boat only has about 275 hours and I never ran it hard, so it is really puzzling that this has happened. Does anyone have any suggestions on how to get this resolved, hopefully with Sea Ray?
Click to expand...
It would be nice to see a few more pics of the other damage areas.
 
From the pictures it looks similar to what happened with our 22 Pachanga in the strake area.
If it's built the same the strakes are cored with wood. At 6 months old the core was pushed up under the engine with a big crack from the hull flexing in rough water.
No visible damage on the outside other than stress cracks in the same area relative to the strakes. Sea Ray fixed it right away but the boat was new.
A loaded boat having one hard hit on a wave could start damage like that.
 
Aren't boats made to hit waves. Hell we would jump our formula in 4 foot waves at 65 mph never had a hull problem. Drives yes hull no
 
spfortjohn said:
Aren't boats made to hit waves. Hell we would jump our formula in 4 foot waves at 65 mph never had a hull problem. Drives yes hull no
Click to expand...

Yes but a bone jarring hit, coming down on one side with the hull hitting flat to a wave, could cause damage.
I'm just saying it's an uncommon possibility. Not properly bunked on a trailer or fork lift could do it too.
My guess is some force was put on the strake between the transom and next forward bulkhead that started the crack some time ago.
Either way it sucks that it shows up when it's about to be sold.

I ran our Pachanga like you did your Formula and never again had a problem after 3 layers of glass were added to the hull.
Now if I pushed it like the race boat it would have been destroyed.
My observation; after heavy solid hulls of the 70's, Sea Ray structural design has been more on the pleasure craft side while Formula leans more toward the high speed performance side.

BrentJones: Have you checked with your insurance? It may be covered if it's from a fork lift or marina storage. :huh:
 
I'm surprised nobody went towards freeze damage. ..from my understanding the boat was kept an a lift all winter? If so all it would take is for the boat to lean a little back and towards the star side to collect enough water in that area to freeze and cause damage and from the water spilling out there was def water in there and enough to give u time to get a camera and take a picture. ..
 
I hate to say it, but, it looks like freeze damage to me. It could have been a small crack from hitting something and water sat in it and froze. The same thing happened to a buddy of mine years ago on a Bayliner. He also cracked a head from freezing.

I don't think people realize the damage freezing can do. If it can expand and crack an engine block it certainly can do some serious damage to fiberglass and gel coat. I am originally from Canada and have seen what freezing water is capable of.

If you can find the point of impact from the bottom, you may be able to claim it on insurance. I would definitely not do anything till you know what caused it and had your insurance company at least look at it.


Steve
 
BrentJones...if you wish, please send me a good number to call you on the PM side and I will be happy to help with this conversation. I can at least get you going in the right direction as has been suggested.

R
 
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