Zodiac Turd Polishing

Phil M · 11 March 2015, 23:10

I figured it was about time I posted my turd polishing project for the last year or so. I bought the boat 2 and a half years ago for a fair price and enjoyed the first years boating. It all started to go wrong however when the engine started to play up and was in need of too much attention. I decided to replace the engine. Whilst it was off, I thought I might as well do a little tidying up too.
This was the starting point...

With engine, a-frame, tubes and console off I turned the boat over and put it back on the bunk trailer for a few months of filling and polishing. The hull was dull and covered in old antifoul, scratches and the off minor dent in the keel.

A good clean and a lot of patient sanding, filling and polishing and it was starting to look a lot better. The keel needed a fair bit of scratch filling and was never going to look good left white as the filler and original gel were slightly different colours. To cover and protect the keel I decided to flow coat it red to match the tubes. New decals were also fitted.

Phil M · 11 March 2015, 23:11

With the hull underside done I flipped the boat back over and sat it on its nice new trailer. All the rollers, fittings etc on the old were shot and the bunks had trashed the hull. I think it was also overloaded as it was un-braked so it now sits on a nice new Nicholson roller trailer.
The next job was to fix a few small hairline cracks in the transom. The gel coat was very thick in some of the corners on the transom returns and around two engine mount holes and had cracked. I ground out the gel (glass was all fine) and replaced with loads of additional CSM to stiffen things up a little more (way bigger than the original crack). I also had to widen the engine cut out as the old mariner was particularly narrow. The old a-frame holes also needed filling and re-drilling.

The console was next. The old one was sturdy but grubby and full of holes. I had always had 2 32l fuel tanks on deck in front but it used deck space and looked crap. I found this one from Ribs4u.co.uk at a very reasonable price which takes a 70l plastic fuel tank with ease.

I ordered the tank and console and set about them. First job was to cut the hatch holes. Found a very handy wire and hose running tool at home too!

I glassed in an additional shelf just above the fuel tank for the battery, in the front section, a storage box under the seat (with access space to fuel tank sender) and ply stiffeners to the insides of the front section for screwing stuff to then flow coated the lot (inside). Hatches were added along with fuel filler/vent and windscreen.

Phil M · 11 March 2015, 23:12

I wanted to hide the cables and wires to the engine. This meant going under the deck. There was already an old exit hole with plug near the transom but on removal just went into the hull void, which offered no protection to any under deck kit. From an old post on here I knew that there were no lateral stringers in the hull so I could run cables from console to transom. I came up with a plan and made some flanges on the lathe to fit 2” suction hose, allowing me to secure it at each end. 2 holes were cut in the deck where the console would be and another next to the existing one at the transom. Using rope and a lot of brute force, I dragged the suction hose through the boat and fitted the flanges. One duct was to feed the engine rigging (battery cables, control cables, fuel and 14 pin harness) and the other for lighting cables, steering lines and any other stuff.
You can see the deck flanges either side of the fuel tank under the console. The green pipe was added to prevent the ducts filling with water as they are sealed from the hull void and will not be easy to drain. No water can enter the hull though of the console floods.

This shows the tube, flange and engine hose through the splash well, before being screwed down.

Phil M · 11 March 2015, 23:13

The hunt for a replacement engine didn’t go well. I wanted more power and a much newer engine and reliability is a must. I looked at the few used suitable engines around and decided on a new Tohatsu or Honda 90. Just before I ordered, the new Merc range was released offering a lighter option than the Honda and more sophistication than the Tohatsu. As the Merc 115 was the same weight as the 75 and 90, I though, bugger it, the hull is rated to 120, why not!
It is BIG! It dwarfs the old 75. It is, however, only as heavy as the 75, aux 4.5 and bracket. The aux won’t fit any more so the transom load is the same.

I opted for the Smartcraft upgrade which, after some fitting queries (see my other posts) is now fully working and, although still big, looks good. It tilts with about 5mm free space under the a-frame. The gauges look great and negate the need for separate trim and fuel gauges.
The down side to smartcraft is the mass of wiring in the console. There is tonnes of it with meters of spare harness coiled up in there. Thankfully it’s a big space so there is still plenty of storage in the upper and lower compartments.
With the new engine came new baystar steering. That was a doddle to fit. I also re-did the electronics with a new lowrance link 8 vhf and Garmin Echomap 50dv. Hopefully these will play nice and the AIS targets will display on the plotter. I can only check that when I get out on the sea.
I also added a compass and a nice stainless bar to stop sun glasses and other stuff falling off the top of the console. All in all I’m pleased with the look and layout.

Phil M · 11 March 2015, 23:19

The final jobs have been to fit all of the various little bits like the 12v socket under the seat (to attach a battery charger or for phone/hand held vhf charging), re-welding and re-fitting the a-frame and general tidying, new light wiring, new antenna, new D-rings, new seat cushion etc. I also painted the deck and fitted a new tank rack. I plan to add a removable cushion to the rack for extra seating when out with the family. It is now pretty much finished and I think is looked quite good. Just need to finish the remaining bits and bobs and then wait for calm weather and initial sea trials.

This is how it now looks......

The next project is to fix up the dive club boat (under the cover in the background).

Phil M

spartacus · 11 March 2015, 23:47

Excellent job.

gareth9702 · 11 March 2015, 23:51

Thanks for posting. It all provides an incentive to push on with my own renovation.

Phil M · 27 March 2015, 21:44

Maiden voyage this evening and wow! With the extra power the boat is a completely different animal. So responsive and quick yet almost silent. I am very impressed with this engine. All the other lor worked perfectly too. Radio and ais all talked to the plotter, console and seat very comfy and the launch was easy on the new trailer. Massive grin factor! Got about 52 kph at 4500rpm but was a bit too rough to push any faster. Next time I'll go with company and try to get some photos.

Phil

HDAV · 27 March 2015, 22:40

Sounds fab.

Ian M · 27 March 2015, 23:31

Enjoyable read. Looks great, good job

Nos4r2 · 27 March 2015, 23:36

Yeah, looks good. I've never helmed one of those-whats it like with that odd hull shape?

jyasaki · 28 March 2015, 16:54

Nice job, Phil. Boat looks sweet. Your workmate looks pretty happy as well.

jky

Leonard Harley · 28 March 2015, 17:52

Impresive

Phil M · 30 March 2015, 12:15

Quote:

Originally Posted by Nos4r2

Yeah, looks good. I've never helmed one of those-whats it like with that odd hull shape?

It's an unbelievably dry ride. The swell and waves were reasonable on Friday, up to about a meter and I don't think we got a drop of water in the boat. It turns very flat, as you might expect but is very stable when stationary, which is perfect for diving. It has a reasonable 1.3m internal beam, so plenty of deck space too. I was always under the impression from previous trips with the original owner and since I bought it that it tended to slam a little in rough water. While not the best hull for really rough weather, having been out with somebody with a lot more experience than I, it seems that with the right helmsman it is not too uncomfortable at all. It really picks up quickly and with a blip of throttle is almost instantly on the plane, although that may be more down to the silent beast on the transom.

I was reading about 1.7 miles per liter at 25mph, so pretty frugal too.

Phil M

Nos4r2 · 30 March 2015, 14:20

That's quite impressive!

AKDoulos · 02 April 2015, 08:17

Would you ever think about using your new Mercury 115hp with a tiller handle on that boat? I'm thinking about getting a 530 pro and converting it to a tiller instead of a steering setup for space and weight. I fish and hunt out of my SU-16 currently and would miss all that space... Thanks.

Phil M · 02 April 2015, 12:45

Quote:

Originally Posted by AKDoulos

Would you ever think about using your new Mercury 115hp with a tiller handle on that boat? I'm thinking about getting a 530 pro and converting it to a tiller instead of a steering setup for space and weight. I fish and hunt out of my SU-16 currently and would miss all that space... Thanks.

I really don't know how it would be but it's quite a lot of power for a tiller isn't it? The biggest tiller outboard I've used was 40hp so honestly can't say. There is a lot of engine movement when you rev quickly though and that makes me think it might be a bit of a hand full. With hydraulic steering I get no feedback from the wheel to judge it on.

Phil M

AKDoulos · 02 April 2015, 18:43

The new big tiller has power steering so I think it should be good as far as the steering response right? I wonder what the difference between hydrolic and power steering is? Do you think the weight in the back of the boat would make it unbalanced? What speed do you have to be going before getting on step? If this is a problem I've thought about buying trim tabs as well.

Phil M · 02 April 2015, 19:12

If the tiller version is damped to take some of the steering forces then that will probably be ok. I assume they wouldn't make it if you couldn't realistically steer it. Power wise, i saw some youtube footage of like for like boats with the 115 4st versus a 125 or 135 opti and the 115 was quicker off the mark and faster overall (and used less fuel). In the 530, it gets the boat on the plane incredibly quickly and is extremely responsive, considering i haven't used full throttle yet. I'm not sure what t he planing speed is but the forecast looks good for sunday so will take a look. I have shifted the console and tank as far forward as possible to keep the balance but this is quite a light engine so the boat seems well balanced. Its not much heavier than my old 75 clamshell and aux. Sadly the aux wont fit the transom with the new engine so i really hope it is reliable!

Phil M

Phil M · 20 June 2015, 20:34

I've finally got a few more hours on the engine and pushed full throttle with a light load. We hit 66kph (just over 40 kph or 35kts) in a light chop. I reckon given better conditions to play with the trim i could get a few more out of it. Revs at 5500 but i don't know if this hit the limiter or not. A prop change might up it too but not sure i need more speed. Hotshot is blindingly fast. Just a shame this summer has so far been so poor for boating.

Phil M