Restoring a classic ski boat - Dr. Jack's 1990 Ski Brendella

[Dano]

@RichardDoane  holy that took a turn.  You guys are into that project now.   Are the. Stringers and foam still serviceable?  

[EFW]

Friends don't let friends buy new boats! Wasn't it Barbera Bush that said "Just say no to new boats"?

[RichardDoane]

@Dano  stringers may be alright but we’ll remove the foam for better analysis. The pylon bracket will need some love, and the wiring harness is going to get a little attention. Marine plywood and some fiberglass work are relatively cheap and easy. The carpet, rotten floor, and motor box scraping has sure filled the dumpster. 

[DvarianDan Johnson]

Yep..... been there - done that. It's a mess but well worth it in the end. Keep up the good work gentlemen. Keep the updates coming. Love to see them    

[Dano]

18 hours ago, RichardDoane said:

@Dano  stringers may be alright but we’ll remove the foam for better analysis. The pylon bracket will need some love, and the wiring harness is going to get a little attention. Marine plywood and some fiberglass work are relatively cheap and easy. The carpet, rotten floor, and motor box scraping has sure filled the dumpster. 

Instead of fixing rotten stringers I’ve thought about making a stainless steel channel that would wrap over the top and both sides of the stringer the length of the motor box and forward to the pylon  mount.  In my case it would take a little messing about to get enough room for the engine mounts to adjust for the width of the added steel but I think it would just be a matter of shaving some material off the mounts.  Would leave you with solid mounting points for the motor mounts and pylon.  

[RichardDoane]

This is all @Horton ‘s fault. 

 

I must’ve changed the oil when we first got the engine up and running. 

Seems like only yesterday. 

Edited May 29 by RichardDoane

[RichardDoane]

I’m glad the engine needed removing, as the transmission is in need of an overhaul. 

We’ll reseal the engine and paint everything pretty. I believe Dr. Jack had the engine replaced at one point in this boat’s life. 

The stringers were a lot worse than we thought. 

I’ll pull the shaft, strut, and rudder in the morning so we don’t have to work around them in the bilge. 

Tomorrow they’ll cut the rotten plywood out of the transom. 

And next week will begin the re-assembly part of the fun. 

[RichardDoane]

The soggy plywood transom removal was a lot more work than anticipated. 

[ReallyGottaSki]

Indeed, transom sux

this close, get the exhaust tips out of your way as well as the rudder. likely some wet wood there as well

[RichardDoane]

we're thinking that we could do without replacing the foam under the floorboards, anybody with input/knowledge ?  @Jody_Seal

[Jody_Seal]

15 minutes ago, RichardDoane said:

we're thinking that we could do without replacing the foam under the floorboards, anybody with input/knowledge ?  @Jody_Seal

pool noodles..

[RichardDoane]

My son can’t help himself, it’s become quite a project. I’ll be dusting off the fiberglassing skills my dad taught me as a kid. 

[DvarianDan Johnson]

Go commando on the foam. Don't replace. I removed all mine years ago when doing the same project.  If not pulling a skier the boat is on the lift in the boathouse. If something were to sink it out in the lake  - that's why I have insurance.  Short of an engine explosion blowing a hole in the hull I don't see it happening.     

[RichardDoane]

We didn’t do much this week due to other projects taking priority, but Casey did put the shine on some of the puzzle pieces. 

[RichardDoane]

I finally removed the rudder, steering bracket, shaft assembly so they could finish cleaning up the floor, transom, and remove the exhaust ports. 

Coats of teak oil on the swim step have begun. 

Coats of teak oil on the swim step have begun. 

[radarvectors]

On 5/6/2024 at 6:04 PM, blakeah23 said:

Love it man! Just got mine on the water and got the mechanical kinks worked out, so now on to the interior. Do you mind sending some more in depth pictures of how the seat bases look, how it is held in place etc? Mostly the observer seat and how that is built would be extremely helpful

My '89 Brendella had the floor re-done & engine rebuilt. The observer seat is missing and we've been using a friggin Tommy Bahama beach chair in it's place.  This has been going on far too long!  I also could use some detailed pics of the seat construction, or links to a place I could have one built, or even a kit would be amazing.  I'm in Yelm, WA on Lake Lawrence, any help would be appreciated.  Glad to see you are still making progress with your boat and look forward to hearing about the finish.

[RichardDoane]

@radarvectors  we have all the old interior pieces that will be copied as the replacements get fabricated (new wood then upholstered). You’re welcome to come take measurements and pics, Yelm isn’t that far from Burien. I’ll post some pics of the old stuff tomorrow. 

[rawly]

Looks like this little beauty gets to continue to build her legacy. She was born and raised at Ski West Village. Has lived here since 1991.  She was a promo for her first year and I am the third owner. It was such a good little boat that I had to buy it for my kids to use here and to take to public lakes. After being towed home to sell , JP stepped up and said get that girl back here. It’s gonna be so cool to see that boat back where it belongs. I was starting to have nightmares about her getting out in the big world after living such a sheltered life. She will be on display at JP’s lot next to the lake 3 docks if any of you national skiers wants to see her 🤣

[RichardDoane]

 Yesterday was gasket-scraping, cleaning, and engine re-assembly. Today it gets a spray can rebuild, and will be ready to re- install once the transmission is ready, and the hull/stringers/floor is back in. 

Edited June 19 by RichardDoane
Typo

[RichardDoane]

It was either going to be an ugly, boring Grey engine enamel, or the bright ass Gloss Aluminum. I went with the over-kill. 

[RichardDoane]

Coat #4 and I think it’s saturated. 

The engine and transmission mounts have all been disassembled and cleaned. Ready for paint. They are actually in decent shape. Will make adjusting much easier when the power train goes back in. 

[RichardDoane]

The transom plywood replacement started today. We opted for 2 sheets of 1/4” in order to get the curve to the hull fitted nicely. Epoxy was thickened in order to become a better bonding agent. They were installing the second layer as I was leaving. Tomorrow they’ll glass it in. It probably took longer to make all the tension blocks and bolt plates that the plywood panel installation. 

[RichardDoane]

@Horton used to ruthlessly drive that boat up on the beach. The glass was worn so thin we added some new layers on the inside. Gelcost guy will fix the outside once the guts are back together. 

I was telling my son about Dr. Jack and his lake. Braden says we should glass a good picture of him into the interior. Hopefully it won’t be one of him in his American Flag Speedo. 

[RichardDoane]

the fuel tank is out of course, and it got a shine this afternoon, now if we could get it as clean on the inside….

Edited June 27 by RichardDoane
Typo

[EFW]

Don't even think of selling that boat!

[RichardDoane]

Shiny Tracking Fins

[RichardDoane]

Rear main seal, bell housing, flywheel, drive plate, and transmission jumped on and received a bomb can rebuild. 

Motor mounts are ready for the new bushings on order from skidim. 

[RichardDoane]

@EFW  that boat will never be sold again, in that we are getting so deep we're going to need to use it for the next 30 years to get our monies' worth from the overhaul

plus, it's going to be a fun thing to ski behind for a change of pace, I'm a biig fan of the new ProStars, but you gotta mix it up sometimes...

[EFW]

1 hour ago, RichardDoane said:

@EFW  that boat will never be sold again, in that we are getting so deep we're going to need to use it for the next 30 years to get our monies' worth from the overhaul

plus, it's going to be a fun thing to ski behind for a change of pace, I'm a biig fan of the new ProStars, but you gotta mix it up sometimes...

You are certainly not going to ski any worse behind that boat. It's a new boat now.

[rawly]

4 hours ago, RichardDoane said:

@EFW  that boat will never be sold again, in that we are getting so deep we're going to need to use it for the next 30 years to get our monies' worth from the overhaul

plus, it's going to be a fun thing to ski behind for a change of pace, I'm a biig fan of the new ProStars, but you gotta mix it up sometimes...

Not to mention , it’s also a fun boat to drive. 

[RichardDoane]

The engine assembly is almost ready. Just adding the accessories that make it function. 

@Jody_Seal did I flip this raw water pump around ?   I took it apart too long ago, and now paint covers  any marks I would have made 

Edited June 29 by RichardDoane
Typo

[Jody_Seal]

looks correct. the screw that holds the inner grate in place oriented towards the engine block on a left rotation engine.

[RichardDoane]

I had Braden and Casey pose for a picture Friday afternoon now that every fastener and attachment had bee removed. Even the shaft log has been cleaned and polished. 

[RichardDoane]

Ignition upgrade parts arrived this morning for the distributor. The Petronix kit is specific to the Prestolite distributor, it’s not the same as a typical small block Ford. Always buy their coil I’ve been told. Wrong coils can take out their electronics. 

Edited July 1 by RichardDoane
typo

[RichardDoane]

Trailer swap this weekend. Luckily for us, winter boat storage turns into summer empty trailer storage, so Brendella got pushed backwards onto a 196 trailer while we do the trailer bunk upgrade to the Brendella trailer. 

[ironhorse]

This is amazing! Thanks for the updates and pics. I love a good resto thread!

[IGski]

This thread makes me want to buy an old classic inboard. Awesome job and loving all the updates.

[03RLXi]

6 hours ago, IGski said:

This thread makes me want to buy an old classic inboard. 

It both does, and doesn't for me!

[Timr71]

Great work! I love this thread...and old boats too!  Keep up the good work and keep posting the pics.  Thanks! 

[rawly]

On 6/18/2024 at 7:43 PM, rawly said:

Looks like this little beauty gets to continue to build her legacy. She was born and raised at Ski West Village. Has lived here since 1991.  She was a promo for her first year and I am the third owner. It was such a good little boat that I had to buy it for my kids to use here and to take to public lakes. After being towed home to sell , JP stepped up and said get that girl back here. It’s gonna be so cool to see that boat back where it belongs. I was starting to have nightmares about her getting out in the big world after living such a sheltered life. She will be on display at JP’s lot next to the lake 3 docks if any of you national skiers wants to see her 🤣

 A couple of very happy girls right there. Let’s just say she loves the wakes of their new Brendella. 

[RichardDoane]

Last week was quickly add 2 bunks to the trailer for support. The fishing boat trailer will need some mods to incorporate the front inner bunks and v-support. 

[RichardDoane]

The pylon got some love by the machine shop, removing almost all of the dings and scratches from use and abuse. The metal bracket was so rusty we had a welder re-create it for install with the new stringers. 

The swim step received a light sanding, and one last light coat of oil. Thanks to @ToddA for the donation in the very beginning of this thread. 

[RichardDoane]

They started creating the stringers this afternoon. Another huge mess I’m afraid. 

Both stringers and an extra section in the middle on each outer side could be ready to start glassing in this week. The old stringers had both fractured where they were notched down for the engine mounts. Adding a second layer seems like the right thing to do. 

[RichardDoane]

Looks like the double wide stringer plan is forming. That way there is good support for the floor. 

[RichardDoane]

At one point today, all the pieces of the puzzle were set in place, but then it’s take them apart to fill any voids prior to glueing them together, and then installing the whole thing into the hull, quite a multi step process. 

[FullFlavorPike]

Nice looking stringers. It’s very cool to see them shaped and ready to be glassed in! I’ve seen plenty of stringer jobs on forums elsewhere; but you’re putting up some of the best photos of the process!

[RichardDoane]

@FullFlavorPike  that flooring system will definitely be over built. My son is in charge. 

[RichardDoane]

Today is sanding of the stringer pieces where the knots and voids have been filled. We probably should have spent the money on top of the line lumber. 

[DvarianDan Johnson]

@RichardDoane- so this boat originally only had the two main stringers but you are adding an additional outboard of the main in each side ? 

[RichardDoane]

Correct. Gives the floor much better support, and will really strengthen the hull. 

End of day gluing together of the stringer pieces. Tomorrow will be some sanding/clean-up and then they’ll be ready to situate in the boat. 

@DvarianDan Johnson  the original stringers had broken where they had been cut down for the engine/trans mounting area. We don’t want that to happen again.