'93 190 Horizon. 20 year revival (Pic heavy)

Jdpber · **Posted:** Fri Oct 17, 2014 8:41 am

Here are the updates.. I did not take any pictures bc fiberglass dust was everywhere and the phone was int he shop.. BUT i have the PORT side trimmed back to where i found solid decking about a foot back from the crappy past repair that was not sealed. So that is good.. All of that crap is cleaned. I plan to try and keep the work site clean every work day to keep things clean lol. Took me some time last night searching for my flush cut flat blade and once i found it about 10pm the dew was falling and i called it a night.. the last 1" of deck at the gunnels that i could not get with the skill saw will have to wait till sunday.

the plans for sunday:

remove the pile of old shit from the starboard side
scrib the line for the straight stern cut and remove the last of both deck sides to a perfectly straight cut
start templating
make up the new Fuel tank dividers. bulkheads.

if i can get the Bulkheads fitted monday and glass wrapped sealed then i should still be on schedule for this week.

master to do list for the week:
finish deck removal and clean edges
MEK (Methel Ethel Ketone) the glue off the gunnels and sand
make bulkhead
glass in bulkheads with drains we cannot for get the drains i have done this in past
DO NOT FOR GET THE DRAINS
template the deck sheets and glass them in
TUESDAY the hatch arrives so i will have to make a router template for it to use to router the hatch pocket out of the floor once it is layed.

The week goal is to have floors fitted and atleast the UNDER side glassed ready for top glass..

I know i have an ambitious goal of having a new cockpit floor installed and glassed in with hatches, nonskid, and paint by thanksgiving before my sons birth. BUT i have to make it happen otherwise the winter temps will delay it for 6 months..

the Bench seat and hatch, on the other hand can be built int he heated shop in a comfortable 65-70* climate int he muffle of the winter.

Jdpber · **Posted:** Fri Oct 17, 2014 3:58 pm

going to look at a new bow anchor over the weekend...

Jdpber · **Posted:** Sun Oct 19, 2014 7:04 pm

well 6 gallons of clear epoxi resin arrived on friday..

at the baby shower on saturday my life long best friend showed up with a surprise of 4 quarts of non skid.. yay free stuff.

deafwish · **Posted:** Mon Oct 20, 2014 2:55 am

I swear the last time I was in Vegas, I bought a bottle of Captain Morgans that looked exactly like this! :shock:

Jdpber wrote:

Jdpber · **Posted:** Mon Oct 20, 2014 8:27 am

hahaha... this is a bit thicker.. the thing that i love the most is it is 50/50 so mixing is a breeze.

the ski locker hatch is UPS out for delivery today so i will have photos of it later tonight.

Today i am working on the router template layout for the hatch gutters and recess so i can print on the plotter at the office tomorrow to make the wooden template guide once i have the exact dimensions of the hatch.

Jdpber · **Posted:** Tue Oct 21, 2014 9:00 am

well last night was busy.. Not many pictures but this is the update.. The hatch arrived and well what was described as a new "Fiberglass ski locker hatch" turned out to be a 1/2 thick STARBOARD hatch.. YAY score even better.. the hardware is perfect and the routed detail in the hatch is simple and will go very well with the boat.. I am overly happy with the decision to purchase vs making and the time that it will save me i feel will be extremely valuable.

I hauled the old: Bench, floor wood, carpet and other junk to the dump. Then headed to the lumber yard to get the marine ply for the floor. i went with 19/32 sheets as they were out of true 1/2" so 0.5937" will do fine a tad thicker will not hurt a thing.

Couple nice large sheets of cardboard from the office yesterday and i will get 2-3 more today and major things will be happening tonight..

Jdpber · **Posted:** Wed Oct 22, 2014 12:53 pm

Last night i got the remainder of the deck removed. The good starboard side about whooped my ass. But is got that some bitch up.. i burned up my last multi tool flush trim blade about half way thru the trimming of the gunnel joints.. at this point i am 4.75 man hours into this project.. YES i am logging all of the man hours to share with people how long various things take.. Last night i also got all of the old Fuel tank hatch supports out. I will syphon the fuel to a few jerry juggs so that i can remove the fuel tank. tomorrow the plan is to make the new bulkheads for separating the fuel tank from the bilge storage and engine room..

Tonights plan. cut out the tiny section under the dash walk thru and finish flush trimming the gunnel joints.. That way i can make a gunnel curve template and get the deck ply cut and fitted. once i have the 2 sheets in i can scribe the final rear seam for a perfect joint with minimal gap..

So far it is very positive vibes for the progress and the vision of finally having a nonskid painted cockpit and new layout..

Jdpber · **Posted:** Thu Oct 23, 2014 8:56 am

ok last night was successful. After buying a new $17 flush cut plunger blade for the multi tool i was able to get a lot of work done in 2.5 hours. The flush cutter is slow BUT it makes a very smooth and flat cut on the gunnels eliminating hours of tedious grinding of old resin seams away. The joints will now only need MEK to remove the carpet glue residue and an 80 grit ruffing to prep for glassing. So in the long run the blade saves a lot of time and DUST..

all of the seams are smooth and we are ready for tempting.. Yes i know that i said it was happening last night but i am meticulous and wanted to take my time on the front end to save me time later..

Clean all the way back to the temp line.. once i lay the ply in i will scribe and cut a perfect line to match the edge of the ply..

detail cutting around the wire scale tubing.. this took some time but it is very neat and i am happy with the results and will be easy to glass in.

rpengr · **Posted:** Thu Oct 23, 2014 3:37 pm

Looks just like what I went through on my 1987 Chaparral (about 5 years ago). However, I paid a small fiberglass shop about $2400 for the marine plywood and glass work including the tear-out. Mine included stringer replacement too, which is tricky because the hull gets real flexible when the stringers are cut out. While it was apart, I fabricated a new Aluminum fuel tank, 50gal, to replace the original 35gal tank. I also added a 6 gal water tank under the floor, but that didn't work out because the hoses got crushed by the new foam as the foam expanded. So the water tank never was usable.

Jdpber · **Posted:** Fri Oct 24, 2014 8:48 am

just bought an entire Serpentine Belt setup for the 5.0 to replace the Vbelt setup.. Brackets, Tensioner, water pump, alternator, power steering pump, smog pump (i will not be needing), crank pulley and harmonic balancer. got a smoking good deal.. this should make the blown Vbelts and squeals disappear.. I freaking cannot stand squeaking belts.. the belts were either always too tight or too loose always needing adjustment.. This will make my life much simpler.

Also i have finished the layout for the non skid borders so i can have the radius cut from viynal at the office and have perfect corers..
light pink is where the non skid will be and the dark outline is th edge that will be 1" of smooth.

rpengr · **Posted:** Fri Oct 24, 2014 9:31 am

Jdpber wrote:

just bought an entire Serpentine Belt setup for the 5.0 to replace the Vbelt setup.. Brackets, Tensioner, water pump, alternator, power steering pump, smog pump (i will not be needing), crank pulley and harmonic balancer. got a smoking good deal.. this should make the blown Vbelts and squeals disappear.. I freaking cannot stand squeaking belts.. the belts were either always too tight or too loose always needing adjustment.. This will make my life much simpler.

Also i have finished the layout for the non skid borders so i can have the radius cut from viynal at the office and have perfect corers..
light pink is where the non skid will be and the dark outline is th edge that will be 1" of smooth.

What did it take to convert to a Serpentine Belt? Seams like a lot of work and components?

Nice layout on the non skid borders. 1" might be a little narrow though... maybe 1.25 or 1.5" along the sides?

Ray

Jdpber · **Posted:** Fri Oct 24, 2014 10:26 am

rpengr wrote:

Jdpber wrote:

just bought an entire Serpentine Belt setup for the 5.0 to replace the Vbelt setup.. Brackets, Tensioner, water pump, alternator, power steering pump, smog pump (i will not be needing), crank pulley and harmonic balancer. got a smoking good deal.. this should make the blown Vbelts and squeals disappear.. I freaking cannot stand squeaking belts.. the belts were either always too tight or too loose always needing adjustment.. This will make my life much simpler.

Also i have finished the layout for the non skid borders so i can have the radius cut from viynal at the office and have perfect corers..
light pink is where the non skid will be and the dark outline is th edge that will be 1" of smooth.

What did it take to convert to a Serpentine Belt? Seams like a lot of work and components?

Nice layout on the non skid borders. 1" might be a little narrow though... maybe 1.25 or 1.5" along the sides?

Ray

I have been thinking the same about the border.. once the floor is glassed i will toss some blue tape down and get a scale view..

You need the: Tensioner bracket, and the 6 spline pulleys. This package the seller had just so happened to have all of the pumps also and for $135 shipped i could not pass up spare parts, Considering the LKQ pick n pull is 45 min each way away and they easy would have charged me this just for the bracket and the pulleys without the pumps. Plus this saved me a saturday of my time as it comes to my door and i do not have to spend time hunting a car with the right stuff down and then pulling it all..

I plan to Paint all of the new pulleys and soda blast the tensioner bracket.. i have not decided between gloss black or a bright blue.. i think the blue may dress it up some along with some chrome valve covers or paint the covers also.. We will see.

as for the work it is not bad, swap a few pulleys and you are good to go. i will have to get the No AC no Smog length belt and a spare. and it will now be a one wrench 10 second new belt install compared to the pain in the ass V belts adjusting 4 different belts.

zims1993 · **Posted:** Fri Oct 24, 2014 11:17 am

I am real interested if you get this serpentine setup to work. Not sure it will work as the power steering pump on the boat looks to be Chevy pump not a Ford pump, and looks to be the same for the alternator. If the shaft diameters are the same it shouldn't be a problem.

I had an 89 5.0 Mustang GT and it took some other purchased brackets to move the power steering pump with no AC to get the belt to work correctly. Search on the internet, tons of threads about 5.0 belt setups using stock parts. The alternator is also on the top left of the motor stock in car and not the bottom like the marine version.

Jdpber · **Posted:** Fri Oct 24, 2014 12:05 pm

zims1993 wrote:

I am real interested if you get this serpentine setup to work. Not sure it will work as the power steering pump on the boat looks to be Chevy pump not a Ford pump, and looks to be the same for the alternator. If the shaft diameters are the same it shouldn't be a problem.

I had an 89 5.0 Mustang GT and it took some other purchased brackets to move the power steering pump with no AC to get the belt to work correctly. Search on the internet, tons of threads about 5.0 belt setups using stock parts. The alternator is also on the top left of the motor stock in car and not the bottom like the marine version.

I am not too worried. i bought all of the front end parts so i should be able to make it work.. this is commonly done to the fox bodies. and being only a couple minor diffs with the marine i am confident that i can make it all work..

zims1993 · **Posted:** Sat Oct 25, 2014 8:27 am

Is the marine version water pump reverse or standard rotation? If I remember correctly you can tell by the outlet of the water pump, the driver side outlet is reverse while the passenger side outlet is standard. Can't remember which year they changed this over in the Mustang.

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'93 190 Horizon. 20 year revival (Pic heavy)

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