Who in their right mind restores a BAYLINER?!

[home made tunnel]

*****EDIT ---> Project started October 2015... Winterized after 4 motors and 3 rebuilds October 2016***




Well, it's a 1997 BAYLINER Capri 1401 LS. Bought it off craigslist for $300! The galvanized trailer alone is worth that, so I took her home.

Started pulling good parts out like controls, steering, wiring, and got carried away!!!

Plans- fiberglass the inside, quick paint job inside and out, a couple seats, and put a 50hp merc I have in the garage on it. Maybe next year throw a bigger motor on :reddevil:

its only 14' and already has a pad on the bottom. Good deal!


****2018 EDIT ****
Boy did that plan above not work out. Opened up a can of worms.


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[home made tunnel]

Started pulling it apart. Found some plywood dropped in by a prior owner, secured with liquid nails and drywall screws!!! Also looks like someone attempted to START removing the gas tank and gave up.

[afr]

i would do that no problem thats how i got all my boats / just plane ole good hard work

[home made tunnel]

Might as well keep ripping it apart! BAYLINER didn't leave any drain holes for the sides- took out about 5 big trash bags full of soaked foam.

got the tank out and found out why someone had tried to remove it! Big ol' HOLE in the bottom corner. Makes the gas tank useless...unless you're a welder like me!!!

[home made tunnel]

Sure enough, rotted transom too. Got it out with a simple pry bar. Then smashed my face with said prybar. Oops.

Another crappy design of BAYLINER--- the top of the transom was never even glassed in! The top half of the hull just sat on top of it, and some angle bracket screwed in. Horrible design. It will be getting glassed in when I put it back together.

[home made tunnel]

Tear down complete! Grinding and sanding is 99% done. Time to rebuild!

[Riverratt]

It looks like your girlfriend passed out in the first picture when she saw you brought home another project.

[Slimm]

Subscribed. Have you made a decision on materials yet?

Slimm

[home made tunnel]

It looks like your girlfriend passed out in the first picture when she saw you brought home another project.

hAHAHA I didn't even notice that until now.


Subscribed. Have you made a decision on materials yet?

Slimm
Yea - Expensive stuff is going towards my tunnel hull. This guy is just getting the plywood treatment. I'll use some solid planks for the stringers, but the bulkheads, seat boxes, and floor will be plywood. I'm thinking either 5/8" or 3/4" for the floor. A layer or two of 6oz 50" wide cloth to seal it all.

Where there was a huge puddle in front of the tank in some of the 1st pictures, I'm going to put a hatch in the floor - Keep access in there for some storage / and to ensure things stay dry.

Still looking for some cheap seats to bolt in.

[home made tunnel]

Stringers and bulkheads are done. New Aluminum tank welded up, decided old one was too SWISS CHEESE to restore. Ready to cut floor pieces out, and start fiberglassing everything in. I'm going to make a false floor cover over the tank so I can remove it for inspection, and another in the fwd section for storage (ancor/rope/empty beer cans etc).

Boy did I open a can of worms. I need to get back to working on my tunnel hull ! ! !

[Robby321]

It looks like your girlfriend passed out in the first picture when she saw you brought home another project.

Damn good eye! And that made my day! Friend mine has a 'Liner like that! Nice little boat!

[olboatman]

It looks like your girlfriend passed out in the first picture when she saw you brought home another project.;)I thought she was part of a custom swim platform!!!:p:D Gary

[FMP]

Lemonade, good job. Pad hull to boot. Hang something decent on it. Leave that 50Merc in the garage, find a good low hour late 90's 120 FORCE , lots around for decent $ and surprise yourself. You'll get hundreds of hours out of it if you stay on top of the tuning and maitenance, and good mpg and mph with the right prop.
I just took another look , for sure add a couple of knees and hang a 120 on it. FUN

[home made tunnel]

;)I thought she was part of a custom swim platform!!!:p:D Gary

She's definitely a fun platform :cool:


Lemonade, good job. Pad hull to boot. Hang something decent on it. Leave that 50Merc in the garage, find a good low hour late 90's 120 FORCE , lots around for decent $ and surprise yourself. You'll get hundreds of hours out of it if you stay on top of the tuning and maitenance, and good mpg and mph with the right prop.
I just took another look , for sure add a couple of knees and hang a 120 on it. FUN

I'll keep an eye out later this winter / early spring. I could just sell this motor for some $ to replace with a bigger spinner

[home made tunnel]

Starting to finish up the deck. I should have made it simple and just put a solid sheet down. Nope, had to get complicated and add storage bulkheads and doors haha.

[W2F a V-King]

Lemonade, good job. Pad hull to boot. Hang something decent on it. Leave that 50Merc in the garage, find a good low hour late 90's 120 FORCE , lots around for decent $ and surprise yourself. You'll get hundreds of hours out of it if you stay on top of the tuning and maitenance, and good mpg and mph with the right prop.
I just took another look , for sure add a couple of knees and hang a 120 on it. FUN

:iagree:....But...If your going to add those knees...why not find an old inline 6 Merc and make it sweet!
Easier maybe to find a good OMC V4. But the "Tower of Power" :thumbsup:

James

Is that Merc 50 and inline 4 cyl? That's one of my all time favorite old Mercs.

[home made tunnel]

332601332602332603

Basecoat down of the outside !

Debating for outer hull colors - Thinking white bottom, black sides, and white deck - Then either red/black graphics on side, OR lime green hull sides with limegreen/black graphics.

[home made tunnel]

332604

AND one for the homies

SOMEONE SELL ME A NICE V4 OMC PLEASE ! ! ! !

[JRider]

In the words of cousin eddie "Shes a beaut Clark" :) She looks great...so does the boat.

[Karsten]

332604

AND one for the homies

SOMEONE SELL ME A NICE V4 OMC PLEASE ! ! ! !

Nice Glass Job....I have a 1971 Evinrude 125 HP V4 and a 1984 Merc 115 hp that need to go

Again, nice glASS

Karsten

[home made tunnel]

Everyone loves the glASS work lol. Shipping from Utah would be a pretty penny to Rhode Island lol

[gotboostedvr6]

I've got a 98 1700XR with a big bore 140 looper, runs 50 with 4 onboard.

Typically Noone wants them so I'm happy to buy them very cheap and beat them for a few years before selling for minimal or no loss.

[home made tunnel]

Bilge coat and another top coat. This will dry and I'll put down the non skid. Then time to flip and clean up the bottom side.
For some reason, the BAYLINER trailers mount their bunks on longitudinal rails. It's impossible to find replacement brackets so I'm making my own. Here I am drilling out new holes.

[FMP]

:iagree:....But...If your going to add those knees...why not find an old inline 6 Merc and make it sweet!
Easier maybe to find a good OMC V4. But the "Tower of Power" :thumbsup:

James

Is that Merc 50 and inline 4 cyl? That's one of my all time favorite old Mercs.

Maybe he doesn't want to spend all of his hard earned money on GAS for those L6s' and V4 OMCs and a little more on his helper!!! You will go further on a tank and just as fast .

[FMP]

Lime green with black !!! I know it's a lot of work but I would try to find 140 CHRYSLER and go through it top to bottom. 78-84 and stick a mid 70's 4 cyl cowl on it . Paint everthing like new. Run a 78-84 1.73 lower with the low side of the bullet water pick ups.REbuild the powerhead , ports , reeds , replace the cd box with a MSD Street Fire. Cut the head for 175 - 185 psi , relieve the exhaust above the cav plate , use a highclearance exhaust snout from a 50-60hp put a 23 high rake prop on it. Set itback and up. Have something real cool. Just saying, real good job!!!

332601332602332603

Basecoat down of the outside !

Debating for outer hull colors - Thinking white bottom, black sides, and white deck - Then either red/black graphics on side, OR lime green hull sides with limegreen/black graphics.

[Instigator]

Very cool thread.

I ignored it initially cuz I just figured it was just another one making fun of another Bayliner owner.
Didn't know there was someone goofy enough to actually restore one ;)

In all seriousness, looks great. It's fun watching one come together w/an owner smart enough to correct the flaws from the factory.

BTW, there's V-4's for sale all over around here.

[home made tunnel]

Lime green with black !!! I know it's a lot of work but I would try to find 140 CHRYSLER and go through it top to bottom. 78-84 and stick a mid 70's 4 cyl cowl on it . Paint everthing like new. Run a 78-84 1.73 lower with the low side of the bullet water pick ups.REbuild the powerhead , ports , reeds , replace the cd box with a MSD Street Fire. Cut the head for 175 - 185 psi , releave the exhaust above the cave plate , use a highclearance exhaust snout from a 50-60hp put a 23 high rake prop on it. Set itback and up. Have something real cool. Just saying, real good job!!!

Ask me about GM LSX motors and motorcycles and I can tell you all about swapping parts between generations and making Frankenstein engines. Now when it comes to Outboards, I'm absolutely clueless. It doesn't sound like a lot of rocket science, but I'm definitely interested in learning!
Do you know of any links where guys documented building engines like that ???



Very cool thread.

I ignored it initially cuz I just figured it was just another one making fun of another Bayliner owner.
Didn't know there was someone goofy enough to actually restore one ;)

In all seriousness, looks great. It's fun watching one come together w/an owner smart enough to correct the flaws from the factory.

BTW, there's V-4's for sale all over around here.
Bayliner owners are pretty goofy ! My friends have always called me the unorthodox guy. They have muscle cars, I have the muscle truck. They have street bikes, Id have the naked streetfighter. They have Harleys, I have my Yamaha cruiser.



Anyway, hoping to get the trailer done today, and get the non-skid painted inside the boat. This weekend hoping to flip it over an take care of the bottom.

[Instigator]

Bayliner owners are pretty goofy ! My friends have always called me the unorthodox guy. .

A bunch of us Hi Perf boat guys used to hang on a local lake, and back in one particular cove. Couldn't see out to the lake from the cove so you'd hear muscle boats coming in before you could see them.
One time we're listening to one idling in and guessing what it was. Could tell it was a radical small block w/a bunch of cam so we're guessing Baja, Checkmate etc.
Out from the trees comes a 24' Bayliner cruiser! Not a low profile cuddy, but a big box of a cruiser!
Was hilarious. Through hull exhaust and everything.

I love that mentality but never did get a chance to talk to the guy. Now whenever I hear a boat before I can see it, I think of that Bayliner ;)

[home made tunnel]

Out from the trees comes a 24' Bayliner cruiser! Not a low profile cuddy, but a big box of a cruiser!
Was hilarious. Through hull exhaust and everything.


That is hilarious. Definitely sounds like something I would do haha. If our season was longer, I'd have bigger aqua toys. I'll have to stick to my little 14' boats for now haha. I meddle in a lot of everything up here in new England. Motorcycles, ATVs, trucks, boats (also sail), and even airplanes.

[FMP]

V4s all over the place, anybody can do that! Make something that nobody has . The recipe works.

[Instigator]

V4s all over the place, anybody can do that! Make something that nobody has . The recipe works.
Agreed.

I was at a boat race in Houston a few yrs back and saw a small Hydrostream bowrider that had a 5 banger Chrysler/Force on it.
Motor was all painted up and had ghost flames on it. Never found that guy either but was one of my favorite boats there.


home made,
most of us find that our first, smallest, simplest boats were our favorites. My first one was also 14' w/a 25 and then a 40 on it. My buddy and I figured out that for $13. (30 yrs ago) , that's $6.50 each, we could gas the boat, buy a qt of 2 stroke, bag of ice, 12 pack and enough tow pig gas to get the boat to the lake for an evening of skiing. We used to go through the week after work and would be the only boat on the lake.
$13!
Almost always had female volunteers offering to go w/us too. Now everyone things you need a 35' cat.
They ain't smart enough to realize, it ain't the boat ;)

[home made tunnel]

Agreed.
Almost always had female volunteers offering to go w/us too. Now everyone things you need a 35' cat.
They ain't smart enough to realize, it ain't the boat ;)

That's the best part ! There's always fem-bots to join. Helps when my "helper" brings girlfriends and sisters :cheers:


This isn't my first go-around with boats. About 5 years ago I bought and restored a 16'6" Checkmate Diplomat. One of the few checkmate bowriders. Had a 120 Force on it, high pitch prop, and was good for about 55mph. Real fun boat, and got me laid quite a few times in the coves behind some islands in RI !

[FMP]

Ghost flames on an F5, different and agreed it isn't the boat.


Agreed.

I was at a boat race in Houston a few yrs back and saw a small Hydrostream bowrider that had a 5 banger Chrysler/Force on it.
Motor was all painted up and had ghost flames on it. Never found that guy either but was one of my favorite boats there.


home made,
most of us find that our first, smallest, simplest boats were our favorites. My first one was also 14' w/a 25 and then a 40 on it. My buddy and I figured out that for $13. (30 yrs ago) , that's $6.50 each, we could gas the boat, buy a qt of 2 stroke, bag of ice, 12 pack and enough tow pig gas to get the boat to the lake for an evening of skiing. We used to go through the week after work and would be the only boat on the lake.
$13!
Almost always had female volunteers offering to go w/us too. Now everyone things you need a 35' cat.
They ain't smart enough to realize, it ain't the boat ;)

[Instigator]

Ghost flames on an F5, different and agreed it isn't the boat.
I'm a hot rod OMC guy so I understand the thing about being different. Trying buying ANYTHING Hi Perf for one.
You don't buy it you make it or pay someone else to.

I love the idea of a hot rod Chrysler, have been saying it for yrs. Not all of us think the holly grail is owning a 300 drag.
It's been done ;)

[FMP]

You might have to make it but then it turns into the accomplishment that only adds to fun. In this case the cool factor with a built " one of " will add to the total. I don't know but keeping it close to home with C/F power will fit the bill ,even a FORCE painted white with the right old cowl tages on it if it was built right. Not to say anything against the v4s. This little boat is light and will be fun. I like these self built threads. Still thinking about those ghost flames on the F5.

[home made tunnel]

Just gotta find me a 120 Force come spring time.
What do folks do to the Force motors to get more power out of them? The extent I'd know about is new thermostat, Waterpump kit, and a fuel pump rebuild. I had a mid 90's force on my last checkmate that never missed a beat. Looked like this one:


333061


In new England, its kinda funny. You want to buy an outboard? It usually comes with a free crappy boat and rusted apart trailer that isn't road-worthy haha

[JRider]

Almost always had female volunteers offering to go w/us too. Now everyone things you need a 35' cat.
They ain't smart enough to realize, it ain't the boat ;)

Or 13 boats in their signature...come up to Erie where the big boys play, 35' cats fit right in. Sorry, do not care for you implying lack of intelligence and correlation to boat size.

[Instigator]

Or 13 boats in their signature...come up to Erie where the big boys play, 35' cats fit right in. Sorry, do not care for you implying lack of intelligence and correlation to boat size.
For real?
Dude if the shoe fits........

I have no problem w/the big go fast boats. Owners w/attitudes, some times.

As to big water on Erie, when I had my first 24' Sonic up there, I was in Leamington Ontario, Pelee Island (also Canadian), as well as the other popular US islands .
On those trips I hardly ever saw the big go fast boats.
Most of those I did see, went the 3 mls to Kelleys Island and went no further.

2nd 24' Sonic was in Fla and did all the Keys multiple times and most of the intra coastal on the east coast.

We stayed on both boats ALL nights, mostly at anchor.

Moved back to Ohio last fall, bought a 22' cuddy for Erie while shopping for a cruiser.
Had it to Huron, Middle Bass and Kelleys. Through 5's a couple times and 7' to 8's once.

Bought a real cruiser in August.
For the couple months of season we had left, we did Pelee twice, Middle Bass, 3 times and Kelleys 3 times. Again, spending all nights on the boat, one at anchor.
How about you?

I list my past boats in my signature to help show experience to those that read my threads/advice not knowing whether to trust me or not.
Not to pick up girls.

Sorry for mucking up your thread home made.

[FMP]

FOR REAL!!!
Erie is fun , if you ever get up on the BAY you might not want to go back.
KEEP looking for that motor, I saw a low hour on a TX add. Late models are good but they need white paint and such greatness. Although they use top guide pistons from 95 on , Merc stuff. THe lower is also Merc so no low on the side bullet water pickup. Basic stuff like squaring ports etc , shaving head 165 psi,slam transfers, better coated Wisecos. Reeds cage work , timing, a bit of jetting no carb covers. It's still almost a CHRYSLER but not that cool .

[JRider]

For real?
Dude if the shoe fits........

I have no problem w/the big go fast boats. Owners w/attitudes, some times.

As to big water on Erie, when I had my first 24' Sonic up there, I was in Leamington Ontario, Pelee Island (also Canadian), as well as the other popular US islands .
On those trips I hardly ever saw the big go fast boats.
Most of those I did see, went the 3 mls to Kelleys Island and went no further.

2nd 24' Sonic was in Fla and did all the Keys multiple times and most of the intra coastal on the east coast.

We stayed on both boats ALL nights, mostly at anchor.

Moved back to Ohio last fall, bought a 22' cuddy for Erie while shopping for a cruiser.
Had it to Huron, Middle Bass and Kelleys. Through 5's a couple times and 7' to 8's once.

Bought a real cruiser in August.
For the couple months of season we had left, we did Pelee twice, Middle Bass, 3 times and Kelleys 3 times. Again, spending all nights on the boat, one at anchor.
How about you?

I list my past boats in my signature to help show experience to those that read my threads/advice not knowing whether to trust me or not.
Not to pick up girls.

Sorry for mucking up your thread home made.

I have had a lot of boats, that's not the point. Your idiotic theory that people with big boats don't get it, is just that...idiotic. You and your long winded BS, I could care less. Actually, you called me stupid...

[Karsten]

I have had a lot of boats, that's not the point. Your idiotic theory that people with big boats don't get it, is just that...idiotic. You and your long winded BS, I could care less. Actually, you called me stupid...

Jrider, how about get over the crap that is a way you started so we members that care about this resto can get back to the project progress....I could care less about how many boats, who has what...hell I have 3 Harley's, 3 boats, 3 Corvettes, 2 H3 Hummers and a couple CAN AM ATV....So what.

This post will end up dead here soon.

Karsten

[JRider]

Jrider, how about get over the crap that is a way you started so we members that care about this resto can get back to the project progress....I could care less about how many boats, who has what...hell I have 3 Harley's, 3 boats, 3 Corvettes, 2 H3 Hummers and a couple CAN AM ATV....So what.

This post will end up dead here soon.

Karsten

Like I said, what you have (or anyone else) is not the point. I give the OP a thumbs-up for what he's doing otherwise I wouldn't have posted. What I don't get is the dumb a$$ comment from instigator.

[Karsten]

Like I said, what you have (or anyone else) is not the point. I give the OP a thumbs-up for what he's doing otherwise I wouldn't have posted. What I don't get is the dumb a$$ comment from instigator.

Owning Corvettes I get his comment if you own C3-C4 Corvettes some of the Elitist that own C5-C7's wont give you the time of day. Some Harley owners wont wave at Metric Owners as they just don't care and with boats it is the same way....If you don't have the newest, the biggest the best you sorta don't count as a boat owner to some.

Personally I like my older stuff, improving on 1971-78 technology and methods....I am sure others wonder what the hell is he wasting time and money with that for.

It is not what you have, how you got it and what the hell you do with it it is how toy treat others and their respect for what they have.......Just maybe someone with a little old 16 ft run about is raising a family and that is all they can afford....but at least they are out there enjoying life and not looking down on people.

Treat others as you would want to be treated....I like the big boats, I like the small boats, I like the new Corvette and I like the really old ones.

Now let's get back to this Awesome Bayliner resto and great glASS work.....Just a joke.

Karsten

[home made tunnel]

iNSTIGATOR's quote" Almost always had female volunteers offering to go w/us too. Now everyone things you need a 35' cat.
They ain't smart enough to realize, it ain't the boat ;)"

Or 13 boats in their signature...come up to Erie where the big boys play, 35' cats fit right in. Sorry, do not care for you implying lack of intelligence and correlation to boat size.

JRider, I think what instigator meant was that girls like the guys, not the boats. Some sarcasm I sensed, and agree with haha.
Theres some toolbags I know of that have $15,ooo jetski's, and never understand why the women are still flocking around me and not them hahaha :cool:
Same goes with some guys I know that have very large boats... It ain't the boat if you know what I mean.

[home made tunnel]

Going to look at a 90hp force for just a hundred bucks tomorrow. I don't see a flywheel on it, but for the price, I'll just rebuild it anyway. Better than a 50! Not as good as a 120

[FMP]

Triples are good, lots of potenial. That one has the Merc lower with speedo tube so your speedo will work. Prob. a 2:1 .thru prop. The water pickup isn't as low as the C/F one piece but you can't interchange it's a MERC leg.Power head is a decent piece with three Tillotson WB ( smaller than TC) or some variation of that. Thunder Bolt IGN, good coils, CDI Electronics has you covered if you can't find spare parts if you need them. All the same mods for the 4 work here. Give it some more ex and square things up and cut out the center bridges, more psi to 165 and cage reed work , tune the carbs a bit more jetting, relieve the cav plate with a couple holes for sound and flow.

[home made tunnel]

Triples are good, lots of potenial. That one has the Merc lower with speedo tube so your speedo will work. Prob. a 2:1 .thru prop. The water pickup isn't as low as the C/F one piece but you can't interchange it's a MERC leg.Power head is a decent piece with three Tillotson WB ( smaller than TC) or some variation of that. Thunder Bolt IGN, good coils, CDI Electronics has you covered if you can't find spare parts if you need them. All the same mods for the 4 work here. Give it some more ex and square things up and cut out the center bridges, more psi to 165 and cage reed work , tune the carbs a bit more jetting, relieve the cav plate with a couple holes for sound and flow.
All great info! I wish there were more write-ups with pictures and such on how to do all that. I have a lot of learning to do on modifying outboards.

[FMP]

THey only go back together one way. The rest you'll get through.Just check out what you are going to buy motor wise thoroughly. No sence buying a engine that is so badly gouged it will not come back.Hear it run, check the comp with a gauge, if one is really in the bad then maybe pull the head and have a look. Check the propshaft for runout and play, have a look at the oil.

[FMP]

Or try one these, 125 HP big carb. This one I think is sold , NicksOutboardMarine in KY . Find one of these with a distributor point ign or Thunderbolt. 4 cyl will better the triple in everyway including the pump on that light boat.

[home made tunnel]

333199

So I bought it. $100!!! Craigslist score! 1995 and smells like mouse piss haha. Still unsure what it all needs but it looks like the block was split at some point as I can see gasket material where it splits, and the guy I bought it from said it was rebuilt at one point. I don't know why the flywheel was pulled, but I ordered a new one for 180 off eBay.

[FMP]

Roll the dice, good on you! 100 bucks! NO turning back now!!!

[Instigator]

iNSTIGATOR's quote" Almost always had female volunteers offering to go w/us too. Now everyone things you need a 35' cat.
They ain't smart enough to realize, it ain't the boat ;)"


JRider, I think what instigator meant was that girls like the guys, not the boats. Some sarcasm I sensed, and agree with haha.
Theres some toolbags I know of that have $15,ooo jetski's, and never understand why the women are still flocking around me and not them hahaha :cool:
Same goes with some guys I know that have very large boats... It ain't the boat if you know what I mean.
Bingo!

Congrats on the new motor.
The Chrysler/Force doesn't make the power as the other brands or offer the aftermarket parts buttttt...., they are cheap anddd way easy to work on. Will look great on your new ride.

[FMP]

With some smart tuning and mods you won't be upset with the power. That one should be a top guided Merc pistons ,rods motor . You will get marked increase if done right, all hands on mods . A thread on here had a triple doing 120+ hp dyno at the prop after mods and E85. Still needs to be white to make real power, HA, HA.

[home made tunnel]

With some smart tuning and mods you won't be upset with the power. That one should be a top guided Merc pistons ,rods motor . You will get marked increase if done right, all hands on mods . A thread on here had a triple doing 120+ hp dyno at the prop after mods and E85. Still needs to be white to make real power, HA, HA.
It's a 95, so I found it is a top guided powerhead.
http://www.maxrules.com/fixphead_force.html#fc3 has the performance reeds for it, and I can dig into it a little more.

http://shop.tsmperformance.net/Powerhead-Rebuild-Kit-for-Force-90hp-1995-1999-TS-100-210-20.htm Has some good prices for the entire powerhead rebuild If I choose to do that. Need to check Comp. 1st.

I might have discovered it only has the Tilt function on it though. I didn't see a trim pump underneath.

[FMP]

Yes it has the pump and single ram trim , so the pic shows. First pull the head, and oil up the sleeves. Put it into gear and turn the prop by hand since you're missing the flywheel. Check for ugly in each hole. Check what pistons are in it. The best thing for your $$ is if you tear it down, and send the block to get done . Save a $$ on labour and get better pistons if needed Wiseco P3151 or P3164 ,looks like the latter. YOu do the porting and reassemble , same with the carbs ,check coils and plug wires for R . go through the trigger and stator and the rest. Get yourself a Seloc paper copy for that motor, best $35 you ever spent. Check all the seals, wrist bearings , mains , easy easy easy. Change the water pump imp, check the L/U .

[home made tunnel]

What's a seloc paper copy?

[home made tunnel]

Finished the bunk brackets for the trailer. Put some paint on them that I had laying around. It'll match the galvanized trailer. Not that I really care what the trailer looks like lol

[FMP]

What's a seloc paper copy?
Seloc manual, get the book keep it at hand when needed.

[whipper]

It looks like your girlfriend passed out in the first picture when she saw you brought home another project.

haha good one.

[whipper]

WOW looking nice great work!!! A better Bayliner. Nice! Your going to have to call her somthing else now because she aint no Bayliner any more.:cheers: Maybe Betterlyner haha http://www.screamandfly.com/attachment.php?attachmentid=332944&d=1449549230

[home made tunnel]

Seloc manual, get the book keep it at hand when needed.

OOooooh - Right right. I just ordered one Sunday, but it was a Clymer. After reading the reviews, the Clymer looked like the better option. But I'll find out when it gets here today by 8pm. (Says amazon delivery!)
http://www.amazon.com/gp/product/0892877324?psc=1&redirect=true&ref_=oh_aui_detailpage_o00_s00



WOW looking nice great work!!! A better Bayliner. Nice! Your going to have to call her somthing else now because she aint no Bayliner any more.:cheers: Maybe Betterlyner haha

Ya, bayliner sucks...
How about... Fire-Liner?
Or... Panty-Liner? ;)

[XstreamVking]

Yours won't fit this desc.since you fixed it up, but when I repaired glass the bayliners were called trash can liners.....

[Riverratt]

Enough of this technical stuff. Post more pictures of your helper :D Keep up the good work. Project can be very rewarding.

[home made tunnel]

So I think the bearings in the 90 are toasted. Or is this the reeds flapping??? Someone enlighten me!!!
What the heck is this clicking sound? Are the bearings gone, and that's the sound of the crank slapping around inside the rods?

https://youtu.be/tbdZFI_ksQM


and here is my 50hp force 1999 to compare. This engine runs fine.

https://youtu.be/x2zGDxt17Fs


So I got some numbers off the top cylinder looking through the spark plug hole. It says 100-205.
The bottom spark plug was very dry and rusted - Middle was OK. Top looked fine.
And just cuz y'all asked - Here's my helper again haha...


333319333320333321

[Riverratt]

I am just impressed that you got your helper to agree to working on a second boat. They usually don't even make it through the first one. what is your secret?

[home made tunnel]

I am just impressed that you got your helper to agree to working on a second boat. They usually don't even make it through the first one. what is your secret?

Like Instagator said... It ain't the boat ;)

[action17]

Like Instagator said... It ain't the boat ;)

Nice!

[Riverratt]

Like Instagator said... It ain't the boat ;)


You da man :thumbsup:

[Riverratt]

I figured you were going to say it was a different helper. I been threatening to do that but the wife wont let me.

[home made tunnel]

She hates the noisy stuff, but loves to paint. She got scared of the Impact when I said "Just pull the trigger!" haha.

So anyone watch the vid and hear the clicking in my 90horse?

[skeeter91]

just pull it apart,you were going to rebuild it anyway right?that powerhead has had water intrusion in the bottom cyl at some point,the internals dont do well with water sitting in/on them for long.noise maker will make itself evident when you look inside i bet!
to bad you not closer,this would be a good one:
http://roanoke.craigslist.org/bpo/5285571877.html

[blackeye]

Enjoying reading the thread. Reminds me of my first boat, a Chaparral 194 converted to a center console with a loop charged 140. That boat had a nice pad and flew. Quite frequently come to think of it. Keep the photos of your handsome craft coming... and more of the boat too ; )

[Instigator]

Enough of this technical stuff. Post more pictures of your helper :D Keep up the good work. Project can be very rewarding.

Blah, hah, hah!

When the wife and I are in line at the ramp and we see a woman back in a trailer or load the boat my wife always asks me if I'm horny.

Relpy is always the same. Hellll Yah!!
I remember watching one back in the trailer and load a 30something Fountain and pull it out like she'd done it a 1000 times.
I couldn't see straight for an hr ;)

[Instigator]

index="1">
Like Instagator said... It ain't the boat ;)

One weekend on my old 24' Sonic cuddy cabin on Lake Erie, we anchored off an island for the night and were the only boat there. The next morning I was making my girl my famous Gary Goulash for breakfast on the beach after paddling in in our $40 Walmart dinghy. Over night a 40something Sea Ray had pulled in and the couple off of it walked by and saw our breakfast cooking on my $20. propane grill. The guys eyes bugged out!

He stopped for a minute, looked at our tiny boat then his huge cruiser, then again at our breakfast. Then says, "I'm on that boat and I'm having cereal for breakfast" and walked away w/o saying another word! Thought his lady was going to kill him!

I sold boats back in the late '80's in Columbus Ohio which is the middle of the state. For shoppers that complained about the areas lack of water, I had a chart of Lake Erie on the wall of my office. It had thumb tacks everywhere that I had been in my $1500. 19' cuddy cabin (that I restored from junk after it and motor were totaled in a fire), and there were many.

I tried to instill in them it's not the boat, it's what you do with it.

Heres a picture of that boat. It crossed Lake Erie many, many times.

Love seeing people do what you're doing. Make it "YOUR" boat and let your personality and creativity show.

Gary

[home made tunnel]

I remember watching one back in the trailer and load a 30something Fountain and pull it out like she'd done it a 1000 times.
I couldn't see straight for an hr ;)

Ha! Totally understand. Too many friendly folk of mine are absolutely terrible at it.


index="1">

One weekend on my old 24' Sonic cuddy cabin on Lake Erie, we anchored off an island for the night and were the only boat there. The next morning I was making my girl my famous Gary Goulash for breakfast on the beach after paddling in in our $40 Walmart dinghy. Over night a 40something Sea Ray had pulled in and the couple off of it walked by and saw our breakfast cooking on my $20. propane grill. The guys eyes bugged out!

He stopped for a minute, looked at our tiny boat then his huge cruiser, then again at our breakfast. Then says, "I'm on that boat and I'm having cereal for breakfast" and walked away w/o saying another word! Thought his lady was going to kill him!

I sold boats back in the late '80's in Columbus Ohio which is the middle of the state. For shoppers that complained about the areas lack of water, I had a chart of Lake Erie on the wall of my office. It had thumb tacks everywhere that I had been in my $1500. 19' cuddy cabin (that I restored from junk after it and motor were totaled in a fire), and there were many.

I tried to instill in them it's not the boat, it's what you do with it.

Heres a picture of that boat. It crossed Lake Erie many, many times.

Love seeing people do what you're doing. Make it "YOUR" boat and let your personality and creativity show.

Gary

I was at the ramp stuck behind some 'tards from Florida who didn't know how to get their 35' fountain center console with triple 300's onto their trailer. We have tides up here in New England that you lake boys and southern folk don't always have to deal with.

They backing in and pulled half way out AT LEAST 15 times, all resulting in their boat too far left or right on the trailer, and being cock-eyed!!! We were all in histerics laughing our ass off at them. THEN their F350 powerstroke blew a tranny cooler line on the ramp and he couldn't pull out, it was all slippery bahahahahahaa. SO I hooked up a strap to my little 5.3L 2011 Colorado, and pulled his truck and boat all out at once, after I had 2 friends hold the boat straight on the trailer. Did it in 1 try.

The good thing was we had beach chairs, and cold beer in the cooler while we were watching this guy.

Sorry if any lake or florida folk get offended by this lol.

[Instigator]

[QUOTE=home made tunnel;2815769 SO I hooked up a strap to my little 5.3L 2011 Colorado, and pulled his truck and boat all out at once, after I had 2 friends hold the boat straight on the trailer. Did it in 1 try.

The good thing was we had beach chairs, and cold beer in the cooler while we were watching this guy.

Sorry if any lake or florida folk get offended by this lol.[/QUOTE]

Hilarious! Would have loved to have seen that.

I'm 56 yrs old and boated all my life. Unloaded/Loaded in wind, current, waves, no power, good ramp, **** ramp, good tow pigg, ****t tow pig.

Pulled Sonic #1 behind a $1500. Chevy van for a while.
Had a 2nd insurance claim on my boat (lower unit Vs shoal and friend side swiped a trailer w/mine) and got cancelled even though I had a $20K loan for the new motors I just installed. Cashed in my 401K, sold everything else I had and paid off the loan and told the insurance co to fk off.

Bought a van off e-bay for $500. w/a 305 cu in smog motor. Spent another grand on a used 350 crate motor, headers, dual exhaust and 3.73 posi. and did a transplant through the drivers door.
Pulled that boat everywhere including up to Canada and a dirt ramp..
Launched at a very questionable ramp one time and had a crowd watch as I tried to pull it out when done. Would get the boat 3/4 way out and up the ramp before the back tires would break loose and stop moving. Tried it several times before getting out to resurvey the ramp.
The lane I was using was wet from everyone else using it. Better water than the 2nd lane beside it though.
A light bulb came on, I unloaded the boat, moved over to the dry side, reloaded the boat and pulled straight out first time and got applause from the spectators.
People say you cant tow w/a van ;)

Heres another oldie but goodie.

[action17]

Blah, hah, hah!

When the wife and I are in line at the ramp and we see a woman back in a trailer or load the boat my wife always asks me if I'm horny.

Relpy is always the same. Hellll Yah!!
I remember watching one back in the trailer and load a 30something Fountain and pull it out like she'd done it a 1000 times.
I couldn't see straight for an hr ;)

agreed!

[tunnels]

Just remember females can do anything !! I taught all my kids at a young age to handle a boat ! what everything was , how it worked etc etc My daughter at the age of 8 could drive the boat without me saying a word !! We always used to practice man over board drill !! which could also be used for picking up a swimmer, or a skier !!OR if I had a heart attack or an accident !! All the kids had to know the weather , the wind , how strong, what direction , how to use the throttle and steer without looking and keeping there eyes glued on the person in the water and never loosing sight of them for a second !! then gently get up close and out of gear , shut off and use the wind drift to bring the boat up alongside and then and help to get them on board !! My daughter at 8 could do it every time never a problem !!The older boys 10 and 12 hardly ever got it right first time .

Man overboard is a good drill to teach your wife and your kids !! never know when they might need to use it !!

[home made tunnel]

That's always good to keep the kids trained too! Now I just gotta work on training my girl to make me a sandwich lol

Man, I hate sanding. Especially bottom coat. Gross stuff.

[home made tunnel]

Started fairing the hull.

Looks like some idiot just replaced cylinder 1, and put the power head back together with red axle grease!!! Wow. Cylinder 3 was the bad bearings I think. That's where all the clicking was coming from.

[home made tunnel]

So the water gasket on the exhaust failed where you can see here. That's what probably leaked into the bottom cylinder.

and it looks like they're bottom guided Pistons too. Is that good or bad?

[Riverratt]

Are you sure it is red axle grease or did they get the gel seal all over the place?

[FMP]

Undo the caps,keep track of everthing don't scribe or mark the rods. Check the crank journals ,pins for water marks ,rust . Check the bores. NOthing wrong with those rods, ever .Even turning 7000+ ,

[home made tunnel]

Definitely red axle grease. It's like the put in the new cylinder without cleaning the block, and never fired it back up again.

Undo the caps,keep track of everthing don't scribe or mark the rods. Check the crank journals ,pins for water marks ,rust . Check the bores. NOthing wrong with those rods, ever .Even turning 7000+ ,


I mi wonder if the guy put the rod cap on backwards. It almost sounded like it was binding. I'm going to try a test fit today and see if it goes together smoothly

[FMP]

Those rods are cracked cap, only line up one way. Big end size is 1.4528/1.4533, small end 0.8767/.8762. Crank pin is 1.1395/1.1391 mains are 1.3752/1.3748. Caps line up edge to edge smooth with rod , no step pencil tip check. Read your book. LOoks like you broke a crank seal ring on the mains. Quick fix one hole, pull it all a part and check everything , clean the block .

[Instigator]

Are you sure it is red axle grease or did they get the gel seal all over the place?
That's what I was thinking too.

Might as well go through the thing now.

I've always said that the safest way to buy a used motor is in a box.

BTW, I'm the one that made the comment about hearing the reads. When I build my OMC V-6's I spin the crank over a bazillion times during reassembly. If doing this w/no carbs you will hear each reed open/close.
Wishful thinking in your case I guess.

[FMP]

Good looking little hull, it's going to be fun. Still not late to find a four banger .

[FMP]

I've always said that the safest way to buy a used motor is in a box.

JUst got that,a little slow on the uptake today. Yes that is the truth.

[home made tunnel]

I hate sandingggggg.
Base coat of black rolled and tipped. I'll keep the fancy spray jobs for the tunnel hull.

[Instigator]

I hate sandingggggg.
Base coat of black rolled and tipped. I'll keep the fancy spray jobs for the tunnel hull.
Looks great.

Nice, efficient hull design too. W/the lifting strakes and pad on the bottom, she'll fly if you screw on enough power.

[home made tunnel]

Two coats on the bottom. A lot of dust and bugs in the paint lol. O well. I'll give it a couple days to harden up (after christmas).

[FMP]

As long as they are water striders, just kidding!

[home made tunnel]

Got it flipped back onto the trailer with the help of a couple friends and family. Yay for light small boats!!! Brought the deck in to start filling some holes and get it paired up with the hull.

Does anyone know where a good place to purchase a sheet of 60"x20" lexan to make my windshield?

[FMP]

UPD Plastics in FL will make you one, or www.cyro (http://www.cyro) / Acrylite for the product . Check out the www.ChryslerCrew.com (http://www.ChryslerCrew.com) site on the windshield replacement build about halfway down the page .

[home made tunnel]

Cut up and glassed in some 2" pic pipe bits to hide all the wires and cables.

And plugged up up some holes.
I also reassembled the rotating assembly and it spun freely with no noise and looked pretty good. I think the last idiot put the bottom cylinder connecting rod cap on backwards. Thus creating a binding situation. I'm going to order 2000's oversized rebuild kit and put the thing back together.

[janetfdoss]

Stringers and bulkheads are done. New Aluminum tank welded up, decided old one was too SWISS CHEESE to restore. Ready to cut floor pieces out, and start fiberglassing everything in. I'm going to make a false floor cover over the tank so I can remove it for inspection, and another in the fwd section for storage (ancor/rope/empty beer cans etc).

Boy did I open a can of worms. I need to get back to working on my tunnel hull ! ! !


Yeah i think you have opened the can of worms.

[FMP]

Cut up and glassed in some 2" pic pipe bits to hide all the wires and cables.

And plugged up up some holes.
I also reassembled the rotating assembly and it spun freely with no noise and looked pretty good. I think the last idiot put the bottom cylinder connecting rod cap on backwards. Thus creating a binding situation. I'm going to order 2000's oversized rebuild kit and put the thing back together.
Check that cap and rod mating surface for chips and hair cracks, if it was on backwards the damage has been done and don't use it. JMO! Those rods are availble used and are plentiful.

[home made tunnel]

Check that cap and rod mating surface for chips and hair cracks, if it was on backwards the damage has been done and don't use it. JMO! Those rods are availble used and are plentiful.

Luckily, it looks as if the engine was never even fired after the new piston was put in. There wasn't even a flywheel installed on it. I think he just pulled the carbs and reed block off, and did the piston swap with the powerhead still attached to the mid. Probably popped off the rod cap and put it back on.

[home made tunnel]

Does anyone have pics or links to the porting jobs?
I'm looking to do some die grinding / burring / porting this afternoon.

[Slimm]

Does anyone have pics or links to the porting jobs?
I'm looking to do some die grinding / burring / porting this afternoon.


I am not exactly sure what porting and grinding you are wanting to do but I'll offer a little of what I have been given/shown. James Perry has a list of engines and the modifications he has done to them located here --> http://www.chattanoogafishingforum.com/forums/thread-view.asp?tid=50919&posts=46&start=1

I hope you can find something that helps you in there.


Slimm

[FMP]

You want to square things up. You can take either the two outside bridges out or the center out of the ex.ports , if you take center out leave 1/4 radius on the new large port, you can raise them a bit and chamfer inside, square roof. The transfers, square them and don't raise them leave a 1/8 corner radius and chamfer inside , square roof. Cut the transfer cover block surface on each enough so the transfer cover just or almost bottoms out with the thickness of the gasket. Cut the head for 165psi. Who's pistons are you using? The ex pic is from an F5 , start with that and square the tops, tr pic is from a CHRYSLER , a bit of a hack job (not mine) but it gives you a start.

[home made tunnel]

So I made a new windshield. Cardboard template transferred to wood. Sanded wood perfect smooth and all that jazz and used a router to cut the acrylic.

Also so added a "V" to the middle to prevent any flexing on the windshield. The bar acts as a grab rail and top windshield mount. A poor design by BAYLINER that I modified. It's very rigid now!

Thanks for for the info on the porting! I'm going to try my hand at it this weekend.

[FMP]

Luckily, it looks as if the engine was never even fired after the new piston was put in. There wasn't even a flywheel installed on it. I think he just pulled the carbs and reed block off, and did the piston swap with the powerhead still attached to the mid. Probably popped off the rod cap and put it back on.
IF it was torqued the unmatched surfaces will have been damaged, take a very close look. Find another rod JMO. The rest looks aces man!

[home made tunnel]

HEREs the kicker question--- what rebuild kit do I buy?!?!
So the piston/rods I pulled out are BOTTOM guided. Which is 1990-1994 style.

My engine comes up as a 1995 serial number E109552 which should be top guided.
So do I buy this kit:
http://shop.tsmperformance.net/Powerhead-Rebuild-Kit-for-Force-90hp-1995-1999-TS-100-210-20.htm

or this one:
http://shop.tsmperformance.net/Powerhead-Rebuild-Kit-for-Force-90hp-1991-94-TS-100-205-20.htm

[FMP]

Put up a picture of the rod and pistons, if it's CHRYSLER/FORCE earlier or MERC later PRoMarine has a kit or many other venders, I say use the Wiseco P3151 .020 over in place of cast pistons. MIght have been a replacement someone put on it when the MERC version blew itself to the moon. Just noticed from an earlier pic that it's running a MERC fuel pump, and the rod looks like a bottom . They did put them together like that. It could be a late run bottom guided or a replaced core . YOu may not need the mains or upper and lower bearings check them and spend the money on the better WIsecos they are lighter and coated to help with crown heat. Since you are running a triple more load on each piston vs a four even though the boat is fairly light with more psi and power you are better off with the p3151.

[home made tunnel]

Put up a picture of the rod and pistons, if it's CHRYSLER/FORCE earlier or MERC later PRoMarine has a kit or many other venders, I say use the Wiseco P3151 .020 over in place of cast pistons. MIght have been a replacement someone put on it when the MERC version blew itself to the moon. Just noticed from an earlier pic that it's running a MERC fuel pump, and the rod looks like a bottom . They did put them together like that. It could be a late run bottom guided or a replaced core . YOu may not need the mains or upper and lower bearings check them and spend the money on the better WIsecos

heres pics. The replaced piston, and the middle one.

Im glad you guys notice the difference in fuel pumps lol. I'm still learning!

[FMP]

Looks like a CHRYSLER/FORCE rod . how about a pic from the big end and cap that was in question? It's 92-95 bottom guided with wrist pin clips. The 91-92 and earier had pressed pins.The clips had me thinking three pistons had been replaced. That first one looks like all cyl need a bore to .020 so things are straight. You can take these to .040 over and more with .050 rings.

[home made tunnel]

Thanks for the info! I'll have to take pics tomorrow of the rod cap in question. So I'm thinking I'll have to buy the rebuild kit for the bottom guided earlier motor

[home made tunnel]

Got the deck all prepped for paint. I'm going to put the two halves together first though. I'm also going to have to figure something out with this horrible BAYLINER engineering woe you can see as a gaping hole at the corners of the transom.

Also almost burned down my garage due to some damn mice.

[FMP]

Wish I knew how to take pics upside down. Those corners have to go, top over bottom then seal it all around , then rivets , then rail and rub trim. If it doesn't want to go then maybe the lower spread out on you a bit after you worked it.

You need to read through the CHRYSLER RACING thread for lots of great pic of triples.
www.youtube.com/watch?v=jtiAF2fWk7I (http://www.youtube.com/watch?v=jtiAF2fWk7I) is a triple that runs strong. Yes bottom guided, but you may not need all of it.

[home made tunnel]

That link didn't work

[FMP]

It was working, a lot of odd things going on. I will post the tread.

[home made tunnel]

Here's a picture of the rod and cap. I didn't pay attention to the cap orientation when I took the cap off but when I put it back on, it sounded fine. What do ya think? I couldn't see any cracks or nicks.

[home made tunnel]

So I'm a better welder than I am caulker. I suck with that sticky stuff. You can see under the bow rail where I made a mess.
By the time I got to the sides I got better. I put 5200 sealant between where the deck overlaps the hull first. Used stainless hardware 1" long 3/16" machine screws with washers and nuts on the inside. A lot stronger than just rivets. You can see my brother who was my hired help for the evening paid with pizza haha. He did all the inside work while I was comfy screwing on the outside

[FMP]

Use rivets they tighten both halves together, what are you backing the screws with???? The rod is your call. Boat looks good. Oh washers and nuts, sure , they are bolts, machine screws.

[home made tunnel]

Ya, machine screws lol. Like these ...

By by the way, I haven't come across any pics of force triples in my searching unfortunately. Even in the Chrysler racing thread

i just noticed that pic uploaded upside down haha. I don't know why, it's right side up in my phone

[FMP]

Ya, machine screws lol. Like these ...

By by the way, I haven't come across any pics of force triples in my searching unfortunately. Even in the Chrysler racing thread

i just noticed that pic uploaded upside down haha. I don't know why, it's right side up in my phone

Here you go straight from the CHRYSLER RACING thread. The triple one of a few shown. The CHRYSLER is the origin of the FORCE. The fours look even better , and the fives well .

[home made tunnel]

Ooooo Purdy!

[home made tunnel]

With some smart tuning and mods you won't be upset with the power. That one should be a top guided Merc pistons ,rods motor . You will get marked increase if done right, all hands on mods . A thread on here had a triple doing 120+ hp dyno at the prop after mods and E85. Still needs to be white to make real power, HA, HA.

I found that guys thread ! Wish there was more pictures about it. I want to learn the 15* of timing advance he put into it.
So being white... That's a Chrysler joke huh? Hahaha, I'm learning... my ignorance is embarrassing.

[FMP]

With the triple block spacing and 120* crank pin spacing the pulse wave returns at about 18 * , 18* , and 13 * prior to ex closing for the tuning pairs at 5500rpm. This is delayed even more than the 4 cyl 30-40* . The range on the triple can be bought in a bit sooner and still make good low end. The practice has shown that an increase in ex duration of 15* is good , that works out to about .045-.050 raise for the 2.8 stroke and still gets the pulse in at the benificial range. Boat weight , load , passengers , skiing tubing, will all show on the low end if the ports are too high, prop changes should get you over the hump. The other mods will also help but a conservative amount with squaring will give good results.

[home made tunnel]

So in laymans terms, it's removing block material from the exhaust ports towards the cylinder head side? Increasing the height .045-.050"?

[FMP]

Yup, the port roof. That will increase the duration time the port window is open and not closed by the piston. What are you tring to achieve with this boat.

[FMP]

This helped for a claimed 10-15hp, with other mods. Transfers before and after.

[home made tunnel]

I really don't have any goals. Just going for whatever I can get for free mods like porting.
With this single ram tilt cylinder, will there be any ability to trim on plane? Or is it too weak? That will really effect top speed if I can't. 65-70 mph would be plenty fun for it.

[FMP]

If the trim isn't leaking it will trim on plane. If it is you will need to repalce an O ring or two. 65 - 70 would be plenty fun but I don't think an 800 lb boat plus you and the triple are going to hit 70 but I could be wrong once you get it up on the pad. But with the proper set up you will have plenty of fun. Yes the four cyl are two carb, some like the 105 are the two carb WB (smaller size ), the triple has three WB. Others like the 140 are TC (larger). You can't swap without making up adapters. Attached is a spec sheet for these, weight is almost the same give or take a pound.

[home made tunnel]

Hmmm - I have a feeling in a month or two I'll be trying out the setup wearing a ski jacket and goggles in the back of the harbour... I will be doing some tubing and skiing with it, so If it's not the fastest out there, I'm fine with that. I can always throw the little 50hp on it haha. The big power will be going on my 14' tunnel hull that i'm 50% done building.

I do have to say these chrysler / force motors are very simple and easy to work on. Tuesday I'll get back into it. Tomorrow is my first day back to work after 2 weeks off, and I need to pick up some more Argon gas for the tig welder after work.

Who knows, maybe I'll put a 120 on it come spring when more pop up on Craigslist.

When you talk about WB and TC, are those different types of carbs??

[FMP]

Carbs, both are Tillotson made. TC are larger than WB . It will run fine, just make sure everything is tuned and set up right , synch and link with the carbs and ign , the jetting, the float levels, the reed and cages they will need work, the right NGK plugs , make sure the plug wires( metal core on these I believe unless someone has switched them) have continuity and the right resistance for the coils primary and secondary, all the stator leads are good , read the book.

[FMP]

So here is CHRYSLER boat and a 140 HPCHRYSLER for a great price. He will put a picture or two up , .
Hmmm - I have a feeling in a month or two I'll be trying out the setup wearing a ski jacket and goggles in the back of the harbour... I will be doing some tubing and skiing with it, so If it's not the fastest out there, I'm fine with that. I can always throw the little 50hp on it haha. The big power will be going on my 14' tunnel hull that i'm 50% done building.

I do have to say these chrysler / force motors are very simple and easy to work on. Tuesday I'll get back into it. Tomorrow is my first day back to work after 2 weeks off, and I need to pick up some more Argon gas for the tig welder after work.

Who knows, maybe I'll put a 120 on it come spring when more pop up on Craigslist.

When you talk about WB and TC, are those different types of carbs??

[home made tunnel]

One dollar!!! Sweet!!!
I'll take it! Waiting for the pics

I ported out just one side tonight to try it out. The center has a thicker gusset area so I knocked out the two side posts. I also increased the height about half a tenth of an inch. .05" for the approximate 15* duration increase What do you think?

[FMP]

Getting brave. Looks like you raised the roof quite a bit. Actually 0.050 will get you less than that. The thing is once its gone its hard to put it back. 2.8stroke needs .0155"/* of height. So 15* duration or about 7.5* height so about .100. I hate to see you go too far , the boat isn't 300lbs.
Just had a look at the boat in the ad. Great package that needs to stay together and get restored , full deal , top off proper. White hull with blue, 17' 231 br with 140HP pt. HydroVee hull, walk through.

[home made tunnel]

Getting brave. Looks like you raised the roof quite a bit. Actually 0.050 will get you less than that. The thing is once its gone its hard to put it back. 2.8stroke needs .0155'/* of height. So 15* duration or about 7.5* height so about .100. I hate to see you go too far , the boat isn't 300lbs.
Just had a look at the boat in the ad. Great package that needs to stay together and get restored , full deal , top off proper. White hull with blue, 17' 231 br with 140HP pt. HydroVee hull, walk through.

It might be closer to 0.100". I'll have to take a pic with my tape measure this afternoon. That one orifice took about 45 minutes to clean up. This could get time consuming haha. I haven't touched the intake side yet.
I spent a good hour just getting all the grime out of it as you could see in one of the earlier pictures. That was nasty, caked on, greasy schmootz!!!

How big of holes do folks drill into the mid section? Does it make it significantly louder?

Also, How much bigger on the jetting do you think it'll need, if any, after this porting? How does one go-about knowing what size jets to go to?

[home made tunnel]

So it's looking right at 0.100" increased height. Maybe slightly less. GREAT!
got the center false floors painted up tonight, and bored another exhaust port. Also bored one intake run by the reed block

[FMP]

Intake run by the reed block? Which reed block did they put in it?

[home made tunnel]

Stock steel reed blocks went back into it. I'm going to get the boyesen reeds.

[FMP]

Describe them . Are they like these ?

[home made tunnel]

Just like those !heres a pic of mine.

[FMP]

More work for you then, the previous design from Chrysler/Force are better. So you need to do some work to them to get them to flow better before you put the reeds in them but then they will help take advantage of the new reeds or you can just run them with new reeds. At least you only have three cages. What was the work you did in the previous post?

[home made tunnel]

Just some work to the inside of the reed cast housing. Look on the left side.
What needs to be done to these reed housings??

i wonder where the closest outboard dyno is to rhode island

[home made tunnel]

1st coat of red. Going to need at least 2 more. Probably 3.

[FMP]

That won't do much. Put the cage in the case and turn it over . Smooth any sharp edges . The block half will need work at the transfer window area , same thing smooth thing up. Don't forget the transfer cover block surfaces cut them down , mentioned it earlier. With that much lift in the ports you will need to cut the head to get the psi back. Put the two halves together and look at how they line up , surface to surface and smooth out any ridges that may be at the inner seam. After ALL the work is done on the block boring , honing, get some good epoxy , Devcon or what ever and add some to the block half in the port side case to stuf it . Where the rod swings by, shape it smooth and do it for each cyl. This is a pic of a race F5 someone did years ago , you get the idea. Don't go crazy with the stuffing just enough. Red looks good

[home made tunnel]

Putting epoxy inside the engine clock worries me,.. How's that motor work out?

[home made tunnel]

Putting epoxy inside the engine Block worries me,.. How's that motor work out?

[FMP]

It works, I would quess a large % of performance builds done buy S&F members know of this or have done it. YOu need to prep the surface ,coarse grit or burr then then clean , brake cleaner or such . Improves the case psi a bit to help the transfer scavenging and signal to the reeds . It is all the little things that add up for the better result.

[home made tunnel]

That makes sense. What do they use as a filler in the epoxy?

[home made tunnel]

So I ordered a rebuilt kit for .030 oversized from Tri State Marine. Also a couple other things. Finished all the porting too. Decided not to do the epoxy filling though. Once I get the kit in,I'm going to consult a local machine shop

Do they sell solid motor mounts for this mid section? While its apart would be the time to put them in. The stock rubber isn't in bad shape, but should prob do it anyway

I tried to put a second coat on the red today, and the underlying layer was just bleeding away. It was still slightly tacky from our new england temps. The mineral spirits in the paint was just kinda melting the first coat. I gave up after just doing the dash. Going to let it dry some more.

[FMP]

Stuffing will help the low mid with the high ex ports. Smooth things out a bit in the transfers. That leg looks like merc mounts so maybe. Did you go wiseco pistons? They make a diff in the weight,and the heat , so you can run a more aggressive tune and live.

[home made tunnel]

A gentleman named Lee from TSM performance gave me this information about their pistons - That they are their own manufacturer, and the pistons are Hypereutechtic cast alloy, MS02 Coated skirts and Hard Coated piston crowns Kit #TS 100-205-20. I got the .030 oversized however.

I'm not too concerned with the low and mid, being that this should be about double the rated power for the boat. Should be plenty to not notice.

So I know the leg is a Merc, but the issue is what the heck mounts to get for it? Are all the mounts for Merc legs universal?

[FMP]

If you want to try the larger TC carbs you can buy them , I know of someone who has a few. Call between 8-10 pm 708- 863-7043 , his name is John.

[Slimm]

The epoxy stuffing will AMAZE you as to how much throttle response it adds as well as the increase low end and midrange 'punch'. I did a fair amount of stuffing when I did my engine the first time, doing it again with some more aggressive porting and an overbore and I am adding even more stuffing to get as much as I can. I used the JB Weld and Steel Stick putties. Both areas show no problems after almost two years of heavy use.


Slimm

334620334621

[home made tunnel]

Carbs, both are Tillotson made. TC are larger than WB . It will run fine, just make sure everything is tuned and set up right , synch and link with the carbs and ign , the jetting, the float levels, the reed and cages they will need work, the right NGK plugs , make sure the plug wires( metal core on these I believe unless someone has switched them) have continuity and the right resistance for the coils primary and secondary, all the stator leads are good , read the book.

http://www.tillotson.ie/products-carb-float.php#TC790
Here's a useful link for the carb specs.
The force 90hp is a 75.1ci motor or... 1230cc. Tillotson says the smaller WB carb is good for 559 - 1200cc. But these come on it, and it's already exceeded. Unless that's per carb... Then it's way under.
I'll look into the larger carbs - Everything helps!
Regardless of everything, It looks like the choke point in the entire engine is still the reed block itself when looking at Area. I have the measurements written down @ home. I'll bring them up later.

[home made tunnel]

The epoxy stuffing will AMAZE you as to how much throttle response it adds as well as the increase low end and midrange 'punch'. I did a fair amount of stuffing when I did my engine the first time, doing it again with some more aggressive porting and an overbore and I am adding even more stuffing to get as much as I can. I used the JB Weld and Steel Stick putties. Both areas show no problems after almost two years of heavy use.



Slimm

334620334621

Hmm - Deff something to think about then. Do you do both sides of the block, or just the side opposite of where the intake goes around the piston skirt?

[FMP]

AS I mentioned earlier you will need to make up an adapter for the TC . You will need to take the WB mount and cut the face off and make up a TC mount, keeping the linkage spacing between throttle cam and roller the same on the bottom carb saves more work.

[FMP]

AS the pic show port side,if you do the transfer side you might take away from the flow into the window. But you could also scallop the bottom of the cyl transfer window and piston on that side , replacing the removed material with stuffing on the starboard side ahead of the window. That could help things but it seems to work better on v blocks .

[home made tunnel]

Lessons learned. Warmed up garage,cold paint (even if thinned), still means the boat is cold and paint comes out like poo. Warm the garage with the heaters and leave it warm for 40 minutes, then use warm paint thinned out and this wet edge paint from Jamestown distributors comes out awesome! I need a few more coats to cover the black you can see on the side showing through. That was my bad planning.

[Slimm]

Hmm - Deff something to think about then. Do you do both sides of the block, or just the side opposite of where the intake goes around the piston skirt?

The 'stuffing' only goes in the crankcase area to reduce the amount of empty air space. When the pistons are on the down-stroke they will compress the same volume of air no matter how big the crankcase area is. By stuffing epoxy in as many places as you can to reduce the crankcase air volume, you force the pistons to compress their same amount of air into a much smaller space, this increases the crankcase pressure (bad in a 4-stroke but GOOD in a 2-stroke), which increases the velocity of air when the transfer ports are opened. The FASTER you can move the air from the crankcase into the combustion chamber, the MORE air/fuel you can move into the combustion chamber. The more air/fuel into the chamber, the more power you can make and in many instances you can make that power more efficiently. In my particular case, I did some minor modifications such as stuffing the crankcase, cleaning up the flash leftover from casting and touching up the exhaust ports and my fuel mileage almost doubled. Went from approximately 2-3 mpg to about 5 and was continuing to get better and make better power the more I fine tuned everything.

I just noticed that I wrote a small book to answer your question, hahahaha. Sorry about that, I'm long winded in person too. :)


Slimm

[home made tunnel]

The 'stuffing' only goes in the crankcase area to reduce the amount of empty air space. When the pistons are on the down-stroke they will compress the same volume of air no matter how big the crankcase area is. By stuffing epoxy in as many places as you can to reduce the crankcase air volume, you force the pistons to compress their same amount of air into a much smaller space, this increases the crankcase pressure (bad in a 4-stroke but GOOD in a 2-stroke), which increases the velocity of air when the transfer ports are opened. The FASTER you can move the air from the crankcase into the combustion chamber, the MORE air/fuel you can move into the combustion chamber. The more air/fuel into the chamber, the more power you can make and in many instances you can make that power more efficiently. In my particular case, I did some minor modifications such as stuffing the crankcase, cleaning up the flash leftover from casting and touching up the exhaust ports and my fuel mileage almost doubled. Went from approximately 2-3 mpg to about 5 and was continuing to get better and make better power the more I fine tuned everything.

I just noticed that I wrote a small book to answer your question, hahahaha. Sorry about that, I'm long winded in person too. :)


Slimm

All good information though ! I was thinking of welding in some aluminum plate in lieu of the stuffing. Then maybe drill a tiny hole like in an airplane window to account for the engine heat cycles.... I'll prob get lazy and just stuff it anyway.

Still searching for an outboard dyno in the New England area.

[FMP]

That side of the block and front case doesn't get the heat. The portside area on the block is backed by the water jacket around the ex chest. Don't sweat it, it will stick with prep.

[MegaBaron]

WOW. some raw mind blowing talent i reckon- complete trailer skids up restoration inside of 3 months, alongside another tunnel boat u home built as well and weldin up fuel tank and deckin' heads, cuttin' and bendin' lexan, porting and matching and honin' in the spare time just to name a few-then postin' it all play by play up here in full detail with pics and all.... and all the while carefully balanced with enuf time for your fiberglass model girly ?!?!? truly remarkable budd. You got me beat all to hell i tell ya what... lik-a dam energizer bunny man. . .
took me 3 months just to organize up a spot just to put my boat in the garage!

[home made tunnel]

That side of the block and front case doesn't get the heat. The portside area on the block is backed by the water jacket around the ex chest. Don't sweat it, it will stick with prep.

I'll get that done after I get the motor parts back from the machine shop. Still waiting for the email confirmation that my parts have shipped. I'm thinking they're probably backordered and aren't telling me yet. I'll have to call them today.


WOW. some raw mind blowing talent i reckon- complete trailer skids up restoration inside of 3 months, alongside another tunnel boat u home built as well and weldin up fuel tank and deckin' heads, cuttin' and bendin' lexan, porting and matching and honin' in the spare time just to name a few-then postin' it all play by play up here in full detail with pics and all.... and all the while carefully balanced with enuf time for your fiberglass model girly ?!?!? truly remarkable budd. You got me beat all to hell i tell ya what... lik-a dam energizer bunny man. . .
took me 3 months just to organize up a spot just to put my boat in the garage!

Haha Thanks ! My alarm goes off @ 4:30am, I get to work for 5:30am. Leave work around 3:30, and head to the shop. I get home around 8pm, shower, eat, play with the gf, and then do it all over again. The woman does get upset sometimes that we don't spend enough time together. That's when I have to wine and dine her, treat her for a night on the town, ya know? I enjoy it too, though. She almost beat me bowling a couple weeks ago! Can't let her do that now!!!!

[FMP]

Make sure you measure up those pistons.Let the machine shop do it if you don't have the tool. You want the clearance right .Ask the supplier what they call for and bore and finish hone each cyl to each piston measurement plus the total clearance. Then hand chamfer all the ports before you put it together. Are you going to equal the weights of the rods and pistons?

[home made tunnel]

Stripped a screw so I had to pull it apart more. What do you think I should do with this can? Leave it in or take it out?

Lastly, do they sell solid mounts for this Mercury leg?

[FMP]

That is the Merc tuner, I know about a 7 " tuner is what some of these triple builds have had with the C/F tuner, but it will add on top and take from the bottom.I think that is the same tuner as the used on the Merc 75 -90 triple. One of the dealers on S&F should know about the mounts.

[home made tunnel]

Not much of an update - but some info...

I got the rebuild kit in the mail, and brought all the parts up to the machine shop to bore the cylinders, chamfer the ports, deck the head .035" for compression, and flat face the exhaust side where there was some corrosion @ the spot the gasket failed, and leaked into bottom cylinder # 3.

So the top mount looked OK after I cleaned it up and inspected it. I snapped 1 of the 4 bolts in the Mid, had to drill it out and re-tap it. I couldn't find solid mounts for the top mount, so back in it goes.

I went to put the main tilt/steering tube back in, and snapped the lower O-Ring in the process. So that re-assembly is also stalled until my O-Ring comes in from CrowleyMarine. I had the wrong shipping address when I ordered it online Friday, but luckily they're mountain time, and I caught it this morning when I called up.

I've got another coat or two to put on the sides, And I can probably start rigging and wiring it up.

Still need to buy a rubrail, and still debating painting the motor WHITE or leaving it as-is and not putting all that extra work into it. Need to buy a skeg too, and get that welded on.

[FMP]

don't forget the transfer cover surfaces. Cut them down to bring the covers in tighter. You want them almost bottomed out with the gasket thickness , so take a cover to the shop. Also take a couple thou off the case to block surface.

[home made tunnel]

Started doing a little rigging today. 5200 marine sealant is very sticky! Battery tray, fuel tank rubber strips and tank tie down anchors. Cleats are back on, and rear pole light base. Fuel Filler cap and bilge drain plug are installed also.

[home made tunnel]

Installed the windshield with some help today. Still keeping the film on it until I get everything squared away.

[Riverratt]

Looking good. Your helper has that same look on her face as my wife gets when I ask her to help me. Lol

[home made tunnel]

Ya know what grinds my gears?
Starting to reassemble the powerhead, and realizing you didn't reorder crank seal rings. DOH !
Delayed another week...

Ya know what grinds my gears?
Pull 12' steering cable out of boat, restore boat, now 12' steering cable is a foot too long...
When in Rome, order expensive Hydraulic steering setup!
Rigging delayed another week...

Ya know what grinds my gears?
Running out of Kerosene, so I can't heat the garage to paint anything
Delayed another 2 days to get up to the north part of the state where they sell it @ the pump.

Ya know what grinds my gears?
Assembling the steering shaft / clamp, and forgetting the bottom oring, having to tear it all the way back down again DOH!

Ya know what grinds my gears?
Setting a dozen mouse traps around the garage, week after week not catching anything...
While working on the bench, a damn mouse runs across it right in front of me !!! I knock over my damn beer trying to squash it !

[FMP]

Which hydraulic steering?

[home made tunnel]

Bay star Hk4200 a-3. I'm going to TIG weld some stainless triangular gussets at both ends where the bar is bent to help eliminate flexing and save myself 300$$$. After all... It'll only be 120hp at most lol. Thinking of picking up a manual jack plate too. Gotta start thinking of props...

[home made tunnel]

It's an awefully big 90hp on a 14' boat lol. Def need a manual jack plate. Centerline of gearcase measures about 10" under the pad!!!! I have 3" to lift with bolt holes on the clamp... So that'd be 7" under pad. Need more height!

[home made tunnel]

^ that's just a teaser pic. I'm thinking the mid, clamp, and lower doing merc black, and both upper and lower cowlings chrysler white... With some red and black pinstripes. So when folks ask what kind of boat or motor I can be like :confused:

[Karsten]

Come on hang a Motor off the back

http://imagizer.imageshack.us/v2/xq90/633/aqxwMz.jpg (https://imageshack.com/i/hlaqxwMzj)

Just a little 150.

Just kidding but the boat is looking awesome and will turn a lot of heads. .

Karssten

[FMP]

Set back?, and just keep the water inlets under when going straight . Turning out very nice. So did yous Karsten. I was on the hunt for a project boat last month and found one. The seller gave me the double triple run around and I still have smoke coming out of my ears. It was that boat I mentioned to you earlier on this thread. O boy the blood pressure is going again. Had it worked out to do a twin 140 Chrysler on a setback with complete core ,trans, seperated , full interior , sun deck , just because I'm nuts and wanted to do some real cool with it . Cash in hand for the seller and he thinks I am a spam or something?????? Even talked to his wife!!! WTF^

[FMP]

Props are easy foe that one, it's merc. t/h.

[home made tunnel]

Karsten, do you have a build thread on that?? Looks fun!!!


Fmp, I still never saw the pics of that boat, but go get it! Lol

[FMP]

No paper work on the boat , so I have to clear it with previous seller and DMV to get it over the border , same with the trailer. It has to be cert. to roll north of the border. I even had a local marina owner call the guy and tell him I was real, he was to do the cert on the trailer. History with boat is likely the reason it's hiding , so just driving down and hooking her up will not get me into the Great White North.

[home made tunnel]

Just bought a jack plate and bolt kit from Bob's Machine Shop - Got the Convertable MJ5 2.5" or 5" setback manual jack plate.

http://www.bobsmachine.com/Convertable-MJ5-25-or-5-setback-manual-jack-plate-200-HP-MAX-100-205000.htm

Nice that it comes anodized black to match the boat ! I think this will look trick with white cowls and black mid/lower.

::::FINGERS CROSSED THE MOTOR RUNS WHEN I PUT IT BACK TOGETHER!!!:::::

[FMP]

Have you gone through the ign ? Not really anything else that would keep you from starting. Unless you are getting temps like we are tonight and tomorrow night @ -27*F with the wind @ -45*F Wind Chill !!!

[Karsten]

Karsten, do you have a build thread on that?? Looks fun!!!


Fmp, I still never saw the pics of that boat, but go get it! Lol

I used to have the previous owners build thread from Sidewinder.com where he had pic's of the new transom, splitting the deck from the hull, repair painting and the rest of the work he had done. he has taken the pic's done now so it is just an empty thread.

This was the way it was when I bought it and over the years the upgrades I have done to the boat.

http://www.fiberglassics.com/glassic-forums/home/the-70-s-disco-fiber/1971-schustr-tahiti-torino

The last upgrades were Hydraulic Steering, Oil Injection, new stereo and speakers, new shift control and all new rigging, new ignition switch, Mercury Smart Craft Monitor, just ordered a 55 MPH white speedo to replace the old chrome one.

It looks like you fab'ed up a new windshield and frame....I like the way that tuned out as well.

[home made tunnel]

Haven't gone through ignition yet. Still waiting for my crank seal rings to come in the mail so I can assemble the power head.
Supposed to be cold here in New England this weekend too. -10 there calling for

[home made tunnel]

So I couldn't do any stuffing to the block. The crankshaft counterweights spin right into that corner.

[home made tunnel]

Gauge face painted, rear hole for rigging cut and sealed, and started on the power head assembly. Had a hell of a time getting the mid bearing races seated without clicking when rotating. That pin in the race seat is a bit$h.

[home made tunnel]

That won't do much. Put the cage in the case and turn it over . Smooth any sharp edges . The block half will need work at the transfer window area , same thing smooth thing up. Don't forget the transfer cover block surfaces cut them down , mentioned it earlier. With that much lift in the ports you will need to cut the head to get the psi back. Put the two halves together and look at how they line up , surface to surface and smooth out any ridges that may be at the inner seam. After ALL the work is done on the block boring , honing, get some good epoxy , Devcon or what ever and add some to the block half in the port side case to stuf it . Where the rod swings by, shape it smooth and do it for each cyl. This is a pic of a race F5 someone did years ago , you get the idea. Don't go crazy with the stuffing just enough. Red looks good
I'd like to see this block with the crank in it!!! How is there enough space for stuffing, unless his crank is shaped differently

[FMP]

Put the rod on and rotate it , fill the void. That block used a slightly different crank.

[FMP]

What is that brown stain on #2 near the top, RUST???
Gauge face painted, rear hole for rigging cut and sealed, and started on the power head assembly. Had a hell of a time getting the mid bearing races seated without clicking when rotating. That pin in the race seat is a bit$h.
Did you cut down the transfer cover surfaces?

[home made tunnel]

What is that brown stain on #2 near the top, RUST???
Did you cut down the transfer cover surfaces?
Covers? Check. Rust? Check. Just a surface spot. Wiped right off. Freezing cold steel in the shop, I turn the heater on and everything in the shop gets dew on it. Like a cold drink in the summertime.

Got the the rotating assembly done and bolted to the adapter plate. Got my bobs manual jack plate today too.

Next problem??? Locating my cylinder head bolts. I kitted everything together when I took it apart? Like carb bolts, exhaust plate bolts, etc. just can't find the bag with head bolts!!!!! Argh.

[home made tunnel]

Why does this site keep flipping my pictures sideways ?!?!

[FMP]

So no stuffing?

[home made tunnel]

So no stuffing?
Negative - Even where the rod swings was very tight. Are you sad ? :(

I can't get the foot throttle in here either with the short snout of this boat, and the way the fiberglass hull tapers in. I could block it up to get some screws in, but then it's just horrible for comfort on the foot. Sooo, I bought a side throttle. BUMMER ! I'll have to save the hotfoot for the tunnel hull. I can't wait to fire this motor up. I'm anxious !

[FMP]

Was it that tight to the forward case as well and to the sides of the reed block area ? With the ports up that much you will need to cut the head to get the psi back.http://media-cache-ec0.pinimg.com/736x/71/5a/cc/715acce67ceaa586d18343f6dde709ca.jpg

[home made tunnel]

Reed case to Piston case, those transfer areas I burred and blended to match. Also from carb plate to reed plate. Also the intake side cover areas. I spent a couple days burring and sanding with air die grinders / burr bits, flap sanding bits. The machinist said it was one of the best hand porting jobs he had ever seen. Post machining, I went at the cylinders again with the sanding flap wheel to chamfer the port edges. There just wasn't any room for the stuffing when I layed in the crank and rods. Look at post #182 where the crank swings. That's only about 1/8" clearance. When the Rod swings through, there's only about a 3/16" clearance. on the sides, and maybe a little more towards the peak of what looks like a bell curve.

The head was cut down 30 thousandths.

[Karsten]

Negative - Even where the rod swings was very tight. Are you sad ? :(

I can't get the foot throttle in here either with the short snout of this boat, and the way the fiberglass hull tapers in. I could block it up to get some screws in, but then it's just horrible for comfort on the foot. Sooo, I bought a side throttle. BUMMER ! I'll have to save the hotfoot for the tunnel hull. I can't wait to fire this motor up. I'm anxious !

A foot throttle on my 16ft wasn't even a thought.....I had to do all new shift controls, cables and what.......Who in their right mind drops $9000.00 into a 45 year old boat?

Now I am figuring out how to mount a 13 gallon bow tank to try to level the boat out a bit.

http://imagizer.imageshack.us/v2/640x480q90/921/AtN0oV.jpg (https://imageshack.com/i/plAtN0oVj)

I need a speedo that goes to 70-80 and I just upgraded to this one that is 55 MPH....I doubt I will ever see 55 but for those wandering around the parking lot might be fun to see the look on their faces.

Karsten

[FMP]

Not so fast with the neg Force comments. World record held .

[home made tunnel]

Heres some updates. Installed the bobs machine shop manual jack plate. Got the cowls painted Toyota supra white.

[home made tunnel]

With the jack plate all the way up and using the highest bolt holes on the clamp, 2.5" below the pad is as high as I can get the motor.
Got the power head together, found out I'm missing one carb gasket, and lost the flywheel key haha. Another week stalled. Still have yet to weld the new Skeg on, and paint The mid and lower.


What do you guys think about getting a bobs nose cone for it? I can't raise it any more, so I don't think the pointy nose cone would help much.

[FMP]

Work the cages, no reed stops and thin strip along the bottom for the screws. No need for carb covers. Motor looks good, everything looks good.

[Karsten]

I just had this discussion with the shop owner that hung the 150 off the back of mine and jack plate or not......What I took away from it was I wasn't building a race and clean water or dirty water......Clean water being 12 inches off the transom and dirty water anything from the transom back to 12 inches. While at the same time the prop has to be in the water completely or you will be sucking up as well as low cooling.

I would dare say you want a little more prop in the water rather than less....Hell, I don't know....

It looks like your Cav Plate and a good half of your prop is going to be out over the water

http://imagizer.imageshack.us/v2/640x480q90/921/mGgg0Q.jpg (https://imageshack.com/i/plmGgg0Qj)

I would think you need to get 2 inches lower to get some water.

Again, I don't know anything more than I have been told lately and I haven't had a chance to put my boat on the water as everything is cover in ice.

Your boat has some awesome style and great work on the windshield.

Karsten

[home made tunnel]

Work the cages, no reed stops and thin strip along the bottom for the screws. No need for carb covers. Motor looks good, everything looks good.
Are you saying to only use the thin metal strip from the new reeds or no strip at all? I did get rid of the large reed stop from the metal factory reeds. I don't have a final picture though. Girlfriend was insisting I come to bed and rushed me LOL

[home made tunnel]

I would dare say you want a little more prop in the water rather than less....Hell, I don't know....

It looks like your Cav Plate and a good half of your prop is going to be out over the water

http://imagizer.imageshack.us/v2/640x480q90/921/mGgg0Q.jpg (https://imageshack.com/i/plmGgg0Qj)

I would think you need to get 2 inches lower to get some water.

Your boat has some awesome style and great work on the windshield.

Karsten

Thanks on the Style points !

I think I'm going to ask the question about height in the "Technical' section of this forum.

[FMP]

This Viper went 85 mph , the Chrysler on it was jacked way up . Just look at were the cav plate would be if the spray wasn't in the pic, that's racing. The reeds need some support along the bottom edge. So a strip as thick as the stop from one side to the other, but just wider than the screws, and a clean edge so not to cut the reeds .

[home made tunnel]

Did you see the unopened package of reeds in my picture? The thin brass strip in that is all that I put on the cages. The factory stop with the three holes is gone.

[FMP]

As long as the strips provide good support without deflection at the screw heads. You could cut thicker ones, those are really Merc cages so depending on who packaged the reeds the instructions might be a bit vague.Use the tread lok. They say to use the factory stops on Chryslers but I don't and at first I did, gained 50 rpm without . Then they said I could run without. I said thanks. They might have edited the instructions , also some small OMCs. Factory stops gone, big clean up ???

[home made tunnel]

I didn't use thread lock. Oops. There's a chance the screws will come out? They're in there pretty tight.

[Velocity72]

Been following the tread and enjoying the progress. Everything looks super. You've gone a long way on a 14' Bayliner....

if if you plan to ski with it at all, you'll be glad for a little prop depth. I would run it with the stock lower before you invest in a nose cone. Sometimes under 60, the cone does more harm than good. Keep up the good work.

[FMP]

Use the thread lok, why take the chance.

[blacktruck]

Been following the tread and enjoying the progress. Everything looks super. You've gone a long way on a 14' Bayliner....

if if you plan to ski with it at all, you'll be glad for a little prop depth. I would run it with the stock lower before you invest in a nose cone. Sometimes under 60, the cone does more harm than good. Keep up the good work.

That's good advice, I would even say unless you are running over 75 or 80, running at an elevated transom height, you don't really need a cone.

[zstyle]

Seconded on the thread lock. Seen it happen. Screw won piston lost.

[home made tunnel]

Got the Skeg welded on, and put a white stripe on the side. Still need to get the black rubrail installed. Too many more things to do ! Really not looking forward to wiring.

[FMP]

Looks good. Hows the oil look? Spring time . Snow this way.

[home made tunnel]

I haven't drained it yet. I left it in to aid in heat dissipation. I only welded half the length at a time, and held the air compressor blow gun on it inbetween passes to keep it cool. the skep tip got hot, but the bullet never got past warm to the touch.

[FMP]

Keep it up right for a day before you drian it. Hope it's not full of eggnog.

[home made tunnel]

A healthy dose of zinc chromate anti corrosion primer !

[home made tunnel]

Dropped the power head, mid, and lower unit onto the jack plate. Had a mini heart attack why I couldn't spin the drive shaft prior to power head install. Turns out there's just resistance with the new water pump haha. Shoulda sprayed in some wd40 or put some motor oil in there. Oh well. Still more wiring to do, helm to install, shifter to drill and mount. Getting there though!!! I had to muscle the damn power head on. No hoist! 💪

[FMP]

NKG plugs. Check all the ign before you put the f/w on.

[home made tunnel]

NKG plugs. Check all the ign before you put the f/w on.

NGK plugs already in it! See the 4th picture in my last post.
Still need to install ignition parts. Just got the flywheel Key in the mail yesterday that I had lost.

Still to do:
1) Wire EVERYTHING
2) Check timing w/ timing light
3) Investigate Main jet size adequate or not. (might need larger).
4) Adjust idle jets once running.
5) Compression test
6) Install Helm
7) Install Shifter
8) get it wet!

[FMP]

When you get the f/w on take the plugs out , get a piece of solder long enough to go in the hole and over the deflector and flat against the crown . Turn the flywheel and squish the solder, pull it out and measure the clearance or do you know the clearance? I can't see the plug name from here.

[home made tunnel]

BUHW plugs by NGK. They're surface fire plugs. No gaps. That's what is run stock on these motors. I forget what the clearance is, but there was room to turn the motor without pistons hitting the head w/ out the head gasket. The head gasket added a little more clearance.

[FMP]

Good plugs, I run them over all others. They have .050 gap that is a bit wider than the Champs. After you check the psi and it has run a few hrs you might want ot tighten it up more. The thing is only three cyl to push the weight so it might want to pre-ign more than a four or five under heavy load. If you run light you can tighten it up more. .045.-.038 in the band on the top of the piston transfer side to the head at TDC. If the psi goes too high cc the head on the ex side to bring it back down to 165-185psi. The tight squish will help push the flame up and put it out to prevent pre-ign.

[home made tunnel]

So I got the battery wired. Fuel tank plumbed. Shift and throttle cables ran. Ignition harness installed (engine side only so far, not key or controls). Power trim solenoids working great. Starter is strong too.
I bought a cheap compression gauge kit on Amazon, and either its reading really low, or brand new engines don't read properly.
Top cyl: 125psi
middle: 125 psi
bottim: 135psi.
Maybe all the oil or wd40 from assembly has drained to the lower cylinder? I was expecting much higher compression.

By the way... I hate wiring FYI. �� Anyone know where all these wires go? Half Mercury, half Chrysler. I have the damn hybrid year of 1995 when they were swapping everything over. Wire colors are half one schematic and half another lol.

[FMP]

Only because everbody does this once, did you have the carbs wide open and all the plugs out? Check it again after the rings work in. 25:1 Merc Oil couple hrs. Wires only go back one way, the right way. Your manual should have a diagram. That ign is Merc ThunderBolt.

[home made tunnel]

That's a negative on the wide open carbs but yes on all the plugs out.

[FMP]

Link and Sync it, make sure carbs are flat open when throttle lever is full forward, make sure carb roller is just touching the throttle cam when in neutral, without fuel and using gun set wot timing , hook up and adjust shift rod to lower ( if done okay) , try not to spin the impeller too much out of water. Final in gear rpm after break in with screw and jamb nut on lower tower at case as you lean out carbs idle screws. Make sure neutral safety switch is set for no out of neutral starts . Hope you set carb floats while you had it apart makes it easier. Check that TDC on #1 is in line with timing marker and flywheel mark, use a pencil down the hole . Check dead middle of TDC with mark , adjust marker to get right on. I have seen them 4* off
Time should be about 32* BTC at WOT , the thing is with the wot timing back off , it will reduce the max timing at wot. On mine , I have adjsuted it to have max timing at wot , I also run about 35-36* static without any problems. If you start at 32 you may find that 33 -34 * works well, listen to it and use good fuel.

[home made tunnel]

So all the wiring diagrams I've found have zero information on this skinny box you see I'm pointing at in this picture. Also, no idea what to do with the purple wire from the cannon plug harness, and the leftover red wire coming out of the switch box (both shown with plugs in them the same picture). Any idea what this box is? No wiring diagrams match it up, even the manual. It's got three wires coming out of the left side, and a single blue coming out of the right.

[home made tunnel]

Which those left over wires remaining, the motor is finally complete!!! Still don't know if it's going to run or if the electronics are good. More to come.
Plugged in the source for my water pressure gauge right on top of the thermostat/block.
im hoping the gray wire coming from the regulator/rectifier will be a good source for the tachometer.

[FMP]

Grey is tack, coils into switch box, triger into switch, stator to reg. and mistery wires go where from where?
Ithought at first merc may have put a limiter on it, but if the original stator was replaced a converter box may have come with it .

[home made tunnel]

I think It's the original stator. Had a date on it from 1996, just like the starter. The mystery red wire comes out of the switch box. The mystery purple wire came out of the engine harness (8 pin plug).

4 wires out of stator. 2 yellow go to regulator/rectifier. The green and green/white go to this skinny mystery box.

Mystery skinny box has the two wires from stator, and a ground wire on the left. Then out the right is a single blue wire that goes into switch box.

Switch box box has the 3 coil pack wires, and the 4 wires from the trigger.
Switch box ask has single blue wire that goes to the mystery skinny box.
Switch box also has mystery single red wire.
Switch box also has single black/ylw wire that I assume is the kill switch. I plugged into black from the engine harness.

[FMP]

The Blk Yel shows on the wire harness to switch box, before you power up call CDI and ask the tech because you might be calling them anyway.

[home made tunnel]

Hmmm... Need to do more reading... This sounds familiar... Red stator, and an adapter box the size of a candy bar...
http://forums.iboats.com/forum/general-boating-outdoors-activities/pwc-jetskis-waverunners-etc/429094-sport-jet-90-black-to-red-stator-conversion-with-pics

[home made tunnel]

What a pain in the ass to install these controls. Cutting the hole, getting all the screws to line up. And holding everything up behind the gunnel while fighting the Twyst of the cables and lining up screw holes that I slightly drilled off location apparently. then come to find out all the wires were upside down so the shift detent wouldn't walk. Outs it all came again! LOL

[FMP]

No bitchin allowed

[Karsten]

What a pain in the ass to install these controls. Cutting the hole, getting all the screws to line up. And holding everything up behind the gunnel while fighting the Twyst of the cables and lining up screw holes that I slightly drilled off location apparently. then come to find out all the wires were upside down so the shift detent wouldn't walk. Outs it all came again! LOL

The new flush mounted control level looks awesome. Check out Faria Dress White gauges if you are still looking in that department and a Schmitt wheel.

http://imagizer.imageshack.us/v2/640x480q90/924/grihkQ.jpg (https://imageshack.com/i/pogrihkQj)

http://imagizer.imageshack.us/v2/640x480q90/923/BZxcVc.jpg (https://imageshack.com/i/pnBZxcVcj)

That is going to be a awesome looking little boat.

Keep up the great work.

Karsten

[home made tunnel]

I already purchased the Arctic gauges. But thank you for the compliments!
That steering wheel is a little too fancy for me lol. I still haven't decided on one yet.

[home made tunnel]

The new flush mounted control level looks awesome. Check out Faria Dress White gauges if you are still looking in that department and a Schmitt wheel.

http://imagizer.imageshack.us/v2/640x480q90/924/grihkQ.jpg (https://imageshack.com/i/pogrihkQj)

http://imagizer.imageshack.us/v2/640x480q90/923/BZxcVc.jpg (https://imageshack.com/i/pnBZxcVcj)

That is going to be a awesome looking little boat.

Keep up the great work.

Karsten
is that's a blue tooth radio you have next to the mph gauge?? How do you like it? What kind is it?

[home made tunnel]

So I learned the adapter module is actually a shunt regulator and the blue wire is the wire that supplies voltage to the switch box. It regulates the voltage to 300 volts by bleeding excess voltage to ground

[Karsten]

is that's a blue tooth radio you have next to the mph gauge?? How do you like it? What kind is it?

That is a Mercury Smart Craft monitor for the engine.......Monitors everything that is going on with the motor, RPM's water temp, engine temp, oil pressure, hours, fuel used and a whole list of other stuff.

Stereo is a simple AM/FM CD player with an SB post and Aux for my 32 GB I Pod.

Karsten

[home made tunnel]

Had to make a bracket for the bilge pump. Also made a bezel for the hydraulic steering helm.

[home made tunnel]

Got the ignition wires up, the tilt/trim wired, and steering helm mounted. Used a spark plug testing light. Turns out we have spark in all 4 cylinders !!! Yay. Marked out top dead center, and the flywheel is only off a couple degrees. Going to set timing next and wire the overheat buzzer.

Now the funky part... Still need to figure out the emergency kill switch. I hooked it up to the black wire with yellow stripe, but while cranking, the motor still had spark. I think I need to revisit this kill switch wire on the shifter.

[FMP]

Right on it grew a cyl! One side stop switch to black the other yel/blk .

[home made tunnel]

Right on it grew a cyl! One side stop switch to black the other yel/blk .
Hahahahaha I meant 3! Must have been the �� Beers last night haha

[home made tunnel]

Had a tough time seeing where the timing was on the black painted flywheel, so I traced it onto masking tape. Also used some TIG welding wire to make a little pointer for easier reading. Timing is set to about 33* BTDC.

Started running the hydraulic steering lines also. What a pain in the butt doing it alone!!! That was a mistake haha.

Used a a ratchet strap to pull all the rigging through my shop vac hose, I mean rigging tube lol. Still gotta put a couple short pieces where it tees off. More to do today and tomorrow.

Going to South Carolina Thursday to Sunday, but maybe next week I'll get to try firing her up!!! Will still have to adjust idle, and mixture screws.

[home made tunnel]

Well... She runs !!! Click the link...

http://youtu.be/C4_G3LQ1rIc

[FMP]

Need a rub strip for the rail . Timing at 33 will get close to 31 at top rpm so try a bit more when tuned in.

[Karsten]

Looks sharp and sounds great. Are you going to add a Transom Saver Brace to the back of the trailer for traveling to and from the water?

Karsten

[home made tunnel]

Need a rub strip for the rail . Timing at 33 will get close to 31 at top rpm so try a bit more when tuned in.
i have the rub rail- haven't put it on yet. Need a nice warm day, and a cooler of hot water.


Looks sharp and sounds great. Are you going to add a Transom Saver Brace to the back of the trailer for traveling to and from the water?

Karsten
yes, just not sure how I'm going to make the bracket for the trail or yet.

[NICE PAIR]

Well... She runs !!! Click the link...

http://youtu.be/C4_G3LQ1rIc

339499 "Nice Job" congrats on the finish.

[99fxst99]

That, sir, is a cool little boat. Why don't kids nowadays see how much more fun these are than a video game???

[vspeedster]

Wow. Fun thread to follow. Really nice job!

[kdtilt]

I have enjoyed the build. You have definitely overachieved. Congratulations from the Chrysler crew!

[home made tunnel]

Thanks everyone!!! Built, not bought !!!
Were supposed to be getting another 8" of snow tonight, which sucks... But giving me some more time to get things finished up.