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View Full Version : Aaronhl's Hydrostream Virage Restoration



Aaronhl
02-18-2019, 07:42 PM
Been on the site for many years, wrote in several threads about this boat but you guys encouraged me to start my own restoration thread so here is goes!! Everyone here has been great answering my questions. I am sure there will be more, so stay tuned in with me guys!!

Bought the Virage from a guy in LI back in 2014, heard the boat has some history and wanted to rebuild it best I could before I got it back on the water. I am already a few years into the restoration and have a couple more. I could list the many things up to now that I would have done differently. I'm trying to balance my time with doing everything correctly without much procrastination if I run into a harder part. I guess in the meantime I can play with my other Stream!!

Since buying the boat at the end of 2014, I have stripped the inside, took the top off, and have been working on the lower half in the garage. It's been in the garage since early 2017. Which up until then it was sitting in the yard while I took all the old wood and foam out. Once I put it in the garage, I was able to concentrate on the epoxy and new wood work. I am hoping to have it out the garage by the middle of this year to put the top back on.

Let me know what you guys think!!

Pictures below:

Aaronhl
02-18-2019, 07:43 PM
http://images.lavignemarine.com/hydrostreamvirage/virage1.jpg


http://images.lavignemarine.com/hydrostreamvirage/virage2.jpg


http://images.lavignemarine.com/hydrostreamvirage/virage3.jpg


http://images.lavignemarine.com/hydrostreamvirage/virage4.jpg


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http://images.lavignemarine.com/hydrostreamvirage/virage8.jpg


http://images.lavignemarine.com/hydrostreamvirage/virage9.jpg


http://images.lavignemarine.com/hydrostreamvirage/virage10.jpg

Aaronhl
02-18-2019, 07:44 PM
http://images.lavignemarine.com/hydrostreamvirage/IMG_1292.JPG


http://images.lavignemarine.com/hydrostreamvirage/IMG_1293.JPG


http://images.lavignemarine.com/hydrostreamvirage/IMG_1319.JPG


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http://images.lavignemarine.com/hydrostreamvirage/IMG_1672.JPG


http://images.lavignemarine.com/hydrostreamvirage/IMG_1683.JPG

Aaronhl
02-18-2019, 07:46 PM
Sorry some of the pictures have the wrong angle

And I will try to dig up the old pictures when I was digging out the old foam and nasty wood.

oldschoolltv
02-18-2019, 07:47 PM
Subscribed, I use to hate the looks of these and now they are growing on me. :)

tnelsmn
02-19-2019, 12:23 AM
Looking good! These things are growing on me as well. Might be the fumes getting to me but I kinda want to do one once I finish my Viking.

LakeFever
02-19-2019, 12:02 PM
Thanks for posting this! I love these resto threads :D

hydrostreamvking4m
02-19-2019, 12:20 PM
Im getting ready to build a stage 3...Please keep the pics comming id like to see all you do with this one...

JrCRXHF
02-19-2019, 12:27 PM
Nice work.

Aaronhl
02-19-2019, 08:07 PM
THanks guys I will keep you updated
Lotta work done and a lotta more work to do

Aaronhl
02-19-2019, 08:15 PM
OK First question for you guys-

Where do I put flotation?

The sponsons will be partially open (the nose will be open about a foot like you can see the center floor is and there will be a transom plug too in each sponson).
The gas tank and battery will take up pretty much all the room in front of the transom.

TwzteD
02-19-2019, 08:48 PM
Cool project, looks good.

rock
02-21-2019, 08:11 AM
Very nice. Gonna be a sharp lookin boat.

Rock

Aaronhl
02-24-2019, 08:54 PM
Ok So here are the pictures when I started the restoration in the back yard in early 2015. I've since bought a better cell phone to take pictures and have a well lit garage to show the progress.


You can see the soggy foam and how much of a mess it was grinding the wood floor from the fiberglass.


Let me know what you think !!

http://images.lavignemarine.com/hydrostreamvirage/IMG_5476.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5477.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5479.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5481.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5722.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5770.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5771.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5773.JPG

Aaronhl
02-24-2019, 08:56 PM
More pics

http://images.lavignemarine.com/hydrostreamvirage/IMG_5777.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5778.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5779.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5786.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5791.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5801.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_5804.JPG

Aaronhl
02-24-2019, 09:03 PM
OK First question for you guys-

Where do I put flotation?

The sponsons will be partially open (the nose will be open about a foot like you can see the center floor is and there will be a transom plug too in each sponson).
The gas tank and battery will take up pretty much all the room in front of the transom.

So I guess previous posts were accidentally deleted, someone posted a picture and description of the flotation foam in their VKing. On each side of the boat there were long pieces of foam from basically the transom to up past the front seats. That is a good idea I will probably go with when I am ready to put my flotation in. Maybe 1ft x 1ft x 8ft foam boxes I can make myself with two part expanding foam or even sheet foam. I didn't want to put it under the floor again.

Aaronhl
02-24-2019, 09:09 PM
When the boat was sitting in the yard before I could put it in the garage, snow caused some damage to the top deck. You can see in some of the first pictures there are cracks right in front of the driver and passenger seat areas. I have since pulled and pried the fiberglass back into place and then fiberglassed the back holding it together. You can still see where the crack formed because I haven't filled and faired it. I really don't want to re-paint the top deck but with all the cracks, oxidation, and splashwell replacement I think I might have no other choice??

XstreamVking
02-25-2019, 08:21 AM
The boxes on my King stayed dry for 30+yrs. I removed the posts to keep your build thread less cluttered. I figured you had seen them.

Aaronhl
02-25-2019, 01:21 PM
I don't mind the clutter, it might help the next guy doin this
Thanks for your ideas about the flotation!!

RONNIE
02-25-2019, 08:10 PM
Looking good!!

Aaronhl
10-07-2019, 05:48 PM
Hi guys more pictures coming soon !!

Aaronhl
10-26-2019, 08:42 PM
Here is a pre winter update, looking back at the pictures I barely remember doing what I did for parts of the restoration...I've been working on it in the garage for so long now. Well I finally put it back on the trailer and took it out of the garage today. Here is the latest work from spring and summer of 2019. Sorry some of the pictures are upsidedown

http://images.lavignemarine.com/hydrostreamvirage/IMG_2517.JPG

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Aaronhl
10-26-2019, 08:50 PM
http://images.lavignemarine.com/hydrostreamvirage/IMG_2835.JPG

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http://images.lavignemarine.com/hydrostreamvirage/IMG_2910.JPG

Aaronhl
10-26-2019, 08:54 PM
http://images.lavignemarine.com/hydrostreamvirage/IMG_2911.JPG

http://images.lavignemarine.com/hydrostreamvirage/IMG_2963.JPG

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http://images.lavignemarine.com/hydrostreamvirage/IMG_3122.JPG

Aaronhl
10-26-2019, 08:59 PM
I haven been running my beat up Valero in the mean time so at least I can have some fun on the water before I finish the Virage

http://images.lavignemarine.com/hydrostreamvirage/IMG_2762.JPG


http://images.lavignemarine.com/hydrostreamvirage/IMG_0514.JPG


http://images.lavignemarine.com/hydrostreamvirage/IMG_2715.JPG

Aaronhl
10-26-2019, 09:04 PM
I bought the Virage used and beat up so it didn't have Hydrostream seats in it. Good thing my Valero has original Hydrostream seats in it because I want to copy them best as I can to use a set in my Virage. So winter project is to make some seat shells and get the reupholstered. Will put a set in the Virage and the Valero

http://images.lavignemarine.com/hydrostreamvirage/IMG_3084.JPG


http://images.lavignemarine.com/hydrostreamvirage/IMG_3092.JPG

Aaronhl
10-26-2019, 09:15 PM
Hope you guys are enjoying the progress. Now that the boat is out of the garage I am going to put the top back on it for the winter with a cover. I had to make some repairs to the top, not all are finished. Getting it ready to install the flat splash-well and top knees in the spring. I will also need to see how well the top fits on the bottom before I take it back off to install the floor mounting strips and wood trim around the top of the bottom of the hull. So I do have a plan and most will be on hold until spring. For now I am going to adjust the trailer.

Also thinking about painting the boat because the gel is really faded. I want to keep the red and black, hopefully I can bring it to a shop that can make it look good. But not sure if I want to get it painted before I rig it up and test drive it a year or so in case more repairs re needed. Easier to prep for paint without everything bolted up...sorry just thinking outloud, hope you guys are enjoying the story

http://images.lavignemarine.com/hydrostreamvirage/IMG_3005.JPG


http://images.lavignemarine.com/hydrostreamvirage/IMG_3006.JPG

tnelsmn
10-26-2019, 09:19 PM
Looking great! I dig how epoxy lays down/cures clear. Looks cool.

oldschoolltv
10-26-2019, 09:21 PM
Keep it up, looks great.

Glastron1987
03-29-2020, 11:09 AM
Like your story. Have a picture of the motor you're going to use?

Aaronhl
04-02-2020, 04:59 PM
Like your story. Have a picture of the motor you're going to use?

this is it so far 200 2.5462025

Glastron1987
04-02-2020, 05:47 PM
Looks good without the rust attached:)

Aaronhl
07-13-2020, 08:58 PM
Started on the Virage again over the past month, repaired the cracks to the top on the sides and bow. Kinda like I was doing some dental work because it had a crazy overbite where it cracked, glad I was able to fix it... The top fits ok on the bottom of the hull, a little uneven gap in the front compared to the sides, but that will be filled with epoxy. I plan to epoxy the top to the bottom all around the seam, originally I was going to fiberglass only the transom area together but to make this boat strong I am going to fiberglass the complete inside seem after filling where needed and then epoxy the gaps on the outside, before putting the rub rail on. I will need to screw the seam together in a few places before I fiberglass it shut. I will also be fiberglassing the cabin sides to the floor, this is unlike other Hydrostreams because the sides are not open. I was originally going to fiberglass a piece of wood on the floor on each side of the cabin to screw the sides of the top, but I feel it would be better to just fiberglass it directly to the floor since I will never take the top off this boat again and like I said the transom area will be all one piece anyway.

I am considering putting carpet on the floor..worried the side seams will not look good so might need to put a filler strip over the carpet where it meets the cabin sides. See pictures below...Any ideas on how to lay the carpet?

Have to epoxy the wood trim to the inside seem on the bottom part of the boat to be able to screw the rub rail into it. Good news is I think I can do that without taking the top off again by working on one side at a time, shifting the top to the opposite side while its on the bottom.

Currently working on the flat splashwell and will posted more pictures from the underside as I'm working on it.

I am finally seeing the end of this restoration, of course a few years behind, wish I could put a motor on it and go, but I feel I need to get it painted before I finish rigging everything because of how awful the finish is now

Aaronhl
07-13-2020, 09:12 PM
https://www.screamandfly.com/attachment.php?attachmentid=469352&d=1594692464


https://www.screamandfly.com/attachment.php?attachmentid=469353&d=1594692498


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Glastron1987
07-14-2020, 07:40 AM
Looking great! For the floor side seam how about getting a small piece of carpet and place it up against the side in place to see how it is going to look?

Aaronhl
07-22-2020, 09:02 AM
Got the flat splashwell in, will be working on filling/fairing and putting more fiberglass over it...

https://www.screamandfly.com/attachment.php?attachmentid=469908&d=1595426416


https://www.screamandfly.com/attachment.php?attachmentid=469909&d=1595426436


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https://www.screamandfly.com/attachment.php?attachmentid=469911&d=1595426532

469908469909469910469911

rgsauger
08-01-2020, 08:57 AM
Your glass work looks great, bud. Brings back a lot of memories of my build. Hard work but pretty awesome when you can stand back and look at what you've done.

Glastron1987
08-01-2020, 03:01 PM
Yeah that will be nice.

Capt.Insane-o
08-01-2020, 11:25 PM
On the splashwell you really need to grind down to glass at least an inch out and bond it in.

Aaronhl
08-02-2020, 09:15 AM
On the splashwell you really need to grind down to glass at least an inch out and bond it in.

Yes that is what I plan on doing. The pictures above were showing setting the new wood in initially. I have a lot of filling and fairing do to to make the splashwell flat, then I will put a later of glass over the whole thing including even several inches of the current red gelcoat. Gonna have to fair after that as well to blend the fiberglass layer in. I am leaving the bottom/underside of the splashwell alone for now (other than a rough filling/fairing to smooth it out) until I am ready to connect the transom knees to the spashwell, which will be fiberglass tabbed in, will also tab in the underside of the spashwell where the new wood pieces connects to the fiberglass. Will keep updating with pictures stay tuned!

Laseraddict
04-25-2021, 04:53 AM
Looking great! It seems like the Valero is much better suited for your boating needs, so just to help you out I'll buy your Virage.. no problem Buddy, just as it sits is fine unless you want to practice a little more glass work, either way is fine.
Boy I would love to find another Virage, almost thought about trying to buy a Hooker bass boat and just getting a Virage deck made-- I gotta find me a Virage again, maybe I'll try to get a new one made some day, or pull off getting that one Arron from Xtreme rebuilt- that one would really be the way to go! Even like 10 years later since it's rebuild now I'm sure it's not cheap (it is for sale again, but probably WAY out of my price range which is why I just gotta find one that's original and needing work to be drivable..
Anyway, your's is looking great, can't wait to see and hear about the rest of the rebuild.

Aaronhl
04-30-2021, 07:40 PM
Looking great! It seems like the Valero is much better suited for your boating needs, so just to help you out I'll buy your Virage.. no problem Buddy, just as it sits is fine unless you want to practice a little more glass work, either way is fine.
Boy I would love to find another Virage, almost thought about trying to buy a Hooker bass boat and just getting a Virage deck made-- I gotta find me a Virage again, maybe I'll try to get a new one made some day, or pull off getting that one Arron from Xtreme rebuilt- that one would really be the way to go! Even like 10 years later since it's rebuild now I'm sure it's not cheap (it is for sale again, but probably WAY out of my price range which is why I just gotta find one that's original and needing work to be drivable..
Anyway, your's is looking great, can't wait to see and hear about the rest of the rebuild.

Thanks for the offer Haha I will have to pass, the point I am at now no money will be worth the effort I have put into the boat. I am slowly making some progress and will keep you guys updated. Will post some pictures of what I've done so far this year when I get a chance

Aaronhl
08-31-2021, 08:20 PM
OK Guys back for another update, slowly getting this thing back together, the top is officially back on the bottom of the hull which means I have fiberglassed the transom/knees/splashwell, rear seem all in one piece now, the majority of the last few months have been on the transom area and just sprayed Duratec sanding primer all over the back tonight. Will post pictures now after I look where I left off in the thread

Aaronhl
08-31-2021, 08:34 PM
492603

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this below is the transom
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the seam all around the boat needed some attention especially in the rear, it needed a lot of epoxy filler
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heres a shot of the inside
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https://www.screamandfly.com/attachment.php?attachmentid=492603&d=1630459379


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https://www.screamandfly.com/attachment.php?attachmentid=492612&d=1630460075

Aaronhl
08-31-2021, 08:49 PM
Will be focusing on the inside as I sand the transom area to get the outside ready for paint
I have already fiberglassed the transom knee structure and the veritcal cabin sides are fiberglass taped to the floor
Will continue to attend to the cabin area there are holes to fill, and of course seats, gas tank, all accessories/rigging

492613

492614

Thats it for pictures, will update with more pictures in a few weeks/months
I can say I have learned a lot over the years on and off working on this boat, it is amazing what using the right tools can accomplish
I never thought the splashwell would have come out the way it did...
I think part of the reason it's taking me so long is because I only want to do this once, every step I have to plan for a little while
I am afraid this thing will be too heavy with the 1/2" ply for the floor and the several gallons of epoxy I have used
Hoping the 12" jack plate I put on will get the tank out of the water
If I did it again I dont think I would put as much care into certain aspects, but this boat is a wide 18 footer and the sponsons have made it more challenging
I am going to do what ever I can on my next build to keep the top attached to the bottom I think

Aaronhl
09-17-2021, 10:30 AM
Been trying to grind out all the spider cracks and fill with epoxy, fair some of the other roughness to prepare for paint
I got a quote from a fiberglass/paint shop on the CT shore line today,
and looks like this boat will continue to stay as a backyard build !!!!!!

Hard to find a boat painter around here, sent messages, called several and only one responded

Glastron1987
09-17-2021, 02:06 PM
Been trying to grind out all the spider cracks and fill with epoxy, fair some of the other roughness to prepare for paint
I got a quote from a fiberglass/paint shop on the CT shore line today,
and looks like this boat will continue to stay as a backyard build !!!!!!

Hard to find a boat painter around here, sent messages, called several and only one responded

Quote was too expensive or other issue?

Aaronhl
09-17-2021, 02:48 PM
Yes too expensive like 10,000
He said to get a quote from an auto body

Aaronhl
09-17-2021, 06:06 PM
Got a pretty nice HIN tag replacement from Garzon Studios
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https://www.screamandfly.com/attachment.php?attachmentid=493275&d=1631919978

Glastron1987
09-18-2021, 08:36 AM
Got a pretty nice HIN tag replacement from Garzon Studios
493275
https://www.screamandfly.com/attachment.php?attachmentid=493275&d=1631919978

Nice

Glastron1987
09-18-2021, 08:43 AM
I bet a body shop will give a better price. On the cheap a roller may work. Can you get the boat up-side-down?

LakeFever
09-18-2021, 01:13 PM
As long as your willing to cut and buff it doesnt really matter how poor the application is you can cut/buff until mirror and spray more if need be. Just sayin dont be afraid of tackling this yourself

Aaronhl
09-25-2021, 01:59 PM
So great weather day sprayed the gelcoat on the transom
Just wanted to paint part of the transom so I can get the outboard jackplate bolted on before winter and then worry about rigging the boat next year/ painting the rest of it. I'll try to use a red/black gradient maybe with metal flake in and around some of the curves so everything will blend.
Ran out of gelcoat because the grey Duratec sanding primer was dark. Needed several coats of red to hind the primer...I think I might sand through a couple areas when polishing the gelcoat

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https://www.screamandfly.com/attachment.php?attachmentid=493576&d=1632596219
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https://www.screamandfly.com/attachment.php?attachmentid=493578&d=1632596336

Aaronhl
09-25-2021, 02:05 PM
As long as your willing to cut and buff it doesnt really matter how poor the application is you can cut/buff until mirror and spray more if need be. Just sayin dont be afraid of tackling this yourself

That is some good advice because I feel I can do it, it won't look like a professional job but atleast I can keep my 10k instead of giving it to someone else :D I'm sure I can make it look pretty good, not looking forward to the wet sanding and polishing part. I gotta tool up to finish the part of the gelcoat finishing

Aaronhl
09-25-2021, 02:11 PM
Heres what the rest of it looks like, had to primer over the epoxy repairs, and the transom primer before todays red gelcoat
I actually like the primer look because it finally hides the ugly repairs I have bee looking at for a couple years

https://www.screamandfly.com/attachment.php?attachmentid=493579&d=1632596964


https://www.screamandfly.com/attachment.php?attachmentid=493580&d=1632596983


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LakeFever
09-25-2021, 02:38 PM
That’s looking really good!

Aaronhl
10-16-2021, 05:46 PM
The weather in Connecticut is staying warm well in October so I have been getting the boat ready
After successfully (in my opinion) wet sanding and polishing the transom/splashwell, I was able to start installing the jack plate
You have no idea how stressful it is to drill fresh holes in the transom after working on it for a few years !!
Looks like I will be able to get the engine on the boat before it gets shrinkwrapped for the winter

Early next spring I will be able to finish more sections of the exterior black/red gelcoat
Even though it will be a lot of work gelcoating the whole boat I am up for the challenge since I can handle it in sections at a time...The hardest part is removing the orange peel during the first sanding, once you can knock the orange peel off, wet sanding is a breeze, and then the machine polisher does the rest of the cutting/polishing
I will get a 320# grit pad for my DA polisher and hopefully that will speedup removing the orange peel

Start with 320# grit wet
400 wet
800 wet
1000 wet
1500 wet
alternate sanding directions between grits
And then cut with 3M Perfect It Gelcoat Heavy Cut
Finish with 3M Perfect It Gelcoat Polish+Wax

I already got a scratch in the transom gelcoat putting on the jackplate !!!

Once the snow stops I will be able to put the boat under the tent again and finsih all the interior items,
I have a switch panel picked out and will need to get a custom gas tank made so I can fit the battery next to it under the splashwell

Will upload more pictures over the winter when I get the lower unit and bucket seats done
Also a picture of the fiberglass seat shells I made, took me over a year to make the mold for them, they are pretty close to matching the original Hydrostream shells I took out of my Valero YT, so they will get reupholstered this winter, I am thinking of white seats with black trim for the bucket seats and rear bench, with a dark gray carpet floor, hopefully that combination looks good

494831
494832
494833
494834
494835

Aaronhl
10-16-2021, 05:51 PM
https://www.screamandfly.com/attachment.php?attachmentid=494831&d=1634424301


https://www.screamandfly.com/attachment.php?attachmentid=494832&d=1634424321


https://www.screamandfly.com/attachment.php?attachmentid=494833&d=1634424338


https://www.screamandfly.com/attachment.php?attachmentid=494834&d=1634424361


https://www.screamandfly.com/attachment.php?attachmentid=494835&d=1634424377

LakeFever
10-16-2021, 06:37 PM
Very nice! Those seat shells look pretty spot on too IMO. Look just like the ones in my Vking

tnelsmn
10-16-2021, 10:53 PM
That 3M Perfect-It Heavy says it will cut 800 scratches. So you can skip the 1500 step and probably the 1000. I stopped at 800 and buffed with mine.

Aaronhl
10-20-2021, 07:35 PM
That 3M Perfect-It Heavy says it will cut 800 scratches. So you can skip the 1500 step and probably the 1000. I stopped at 800 and buffed with mine.

Yea I saw that too...Maybe on the next application I will go up to 1000 just to be safe rather than 1500

rgsauger
10-21-2021, 08:00 AM
So tell me more about how you made your seat shells. I'm disappointed in what's out there that fits my boat so might be doing the same. Would probably use wood inside but would like to see more pics if ya got 'em. I think the black "windshield" looks killer.

When that hull is up flying, are the sponsons 100% out of the water? Looks a little like the bottom of my Shadow at the tail end which is like a Laser/STV.

Awesome thread

tnelsmn
10-21-2021, 08:38 AM
Yea I saw that too...Maybe on the next application I will go up to 1000 just to be safe rather than 1500

Just trying to save you some time. That Perfect-It is some good stuff. We did some side by side testing with other compounds and that was much better.

Boat is looking good! Can't wait to see you float it.

Aaronhl
10-21-2021, 09:57 AM
So tell me more about how you made your seat shells. I'm disappointed in what's out there that fits my boat so might be doing the same. Would probably use wood inside but would like to see more pics if ya got 'em. I think the black "windshield" looks killer.

When that hull is up flying, are the sponsons 100% out of the water? Looks a little like the bottom of my Shadow at the tail end which is like a Laser/STV.

Awesome thread

Here is the mold I made designed from the original seat, its a reproduction not molded directly off the Hydrostream seat shell, the Hydrostream seat shells are flimsy and non symmetric, so some of the dimensions I averaged, however overall shape and sizes are pretty close, I made the mold a little bigger in case I want to cut the arm rests differently if needed for a different design, for the first several I've pulled out of the mold I used a lot more fiberglass than I needed to...

The shells are wrapped on both sides by 1" thick foam, making the overall thickness of the seat a little over 2" wide, the vinyl seat cover goes over the foam and then stapled to the wood base (which I also have the template for)...I will be sure to post pictures as I do more work on the seats...

https://www.screamandfly.com/attachment.php?attachmentid=495055&d=1634828274


https://www.screamandfly.com/attachment.php?attachmentid=495056&d=1634828291


https://www.screamandfly.com/attachment.php?attachmentid=495057&d=1634828356


https://www.screamandfly.com/attachment.php?attachmentid=495058&d=1634828381


https://www.screamandfly.com/attachment.php?attachmentid=495059&d=1634424301


https://www.screamandfly.com/attachment.php?attachmentid=495060&d=1634828430

495055

495056

495057

495058

495059

495060

Aaronhl
10-21-2021, 10:16 AM
So tell me more about how you made your seat shells. I'm disappointed in what's out there that fits my boat so might be doing the same. Would probably use wood inside but would like to see more pics if ya got 'em. I think the black "windshield" looks killer.

When that hull is up flying, are the sponsons 100% out of the water? Looks a little like the bottom of my Shadow at the tail end which is like a Laser/STV.

Awesome thread

Thank you

I think the outside sponsons will still be in the water a little bit at least touching to give it some stability, from the videos Ive seen...I havent put it on the water myself yet....

I plan on extending the black windshield about 1.5 ft closer to the transom when I spray it with black gelcoat

Aaronhl
10-21-2021, 09:18 PM
Ok my dad helped me tonight with tightening the jack plate on the boat, finally get to put the engine on

https://www.screamandfly.com/attachment.php?attachmentid=495093&d=1634869022


https://www.screamandfly.com/attachment.php?attachmentid=495094&d=1634869037


495093

495094

rgsauger
10-21-2021, 09:51 PM
Awesome pics and write up on your seats. That’s way cool. Do they seem pretty strong? 1708 cloth? How many layers in your fg layup? Epoxy or regular resin?

Aaronhl
10-22-2021, 08:11 AM
Awesome pics and write up on your seats. That’s way cool. Do they seem pretty strong? 1708 cloth? How many layers in your fg layup? Epoxy or regular resin?

Thank you Yes they seem strong but I didnt build them thick so they wouldnt flex. I wasnt sure how many layers of fiberglass I needed. On those seats I posted, I used 3 layers of 18oz Woven fiberglass and about a quart of polyester resin (per seat) which makes them about 1/16" thick, I did double the layers to 6 in the inside corner you can see in the pictures...to make them look like the originals, you have to make the shell flex on the arms rests as they spread when you pull the vinyl cover over...

Smalltownbassin
10-22-2021, 01:54 PM
Cool project!

Aaronhl
05-28-2022, 02:33 PM
So maybe I said this before but bought the Virage in December of 2014, Didn't start working on it until Spring of 2015, so now that Spring is here once again in 2022 that makes this a 7 year on and off project. I keep getting deeper into this thing because I am trying to do as much of the work myself and learning as I go along, Never thought I'd be doing as much as I am doing on this boat,,,anyways here's the latest update:

Finished the transom/splashwell last year putting gelcoat on it, put the engine on the 12" jack plate (working on a lower unit w/ nosecone now) and then shinkwrapped it
Started this year with more fairing of the top and sides using epoxy filler and grey Duratec surfacing primer to seal the epoxy before spraying gelcoat over it
A whole bunch of filler went into this project and so far even more sanding, +more sanding :)
Now that the temperatures are higher, started spraying red/black gelcoat on the lower half and will need to spend a lot of time wet sanding it
Will now focus on the top deck and cabin as I need to sand the primer and then spray gelcoat over it.
The black gel goes over the original black very easily, however the red gel goes on almost translucent so it takes MANY coats to hide the gray primer, I am not looking forward to spraying the top and cabin
But I am satisfied with the job nonetheless because I have not sprayed much gelcoat, only several months ago was my first time spraying with a compressor+hvlp...

If I missed something let me know

Posting the pictures chronologically, as the first several show the boat sanded getting read for paint, and then the last show the gelcoat as it sits now

https://i.imgur.com/cjvwIMq.jpg

https://i.imgur.com/5BRtKR8.jpg

https://i.imgur.com/vntpfUi.jpg

https://i.imgur.com/oRD2XQH.jpg

https://i.imgur.com/eAbkRyk.jpg

Aaronhl
05-28-2022, 02:33 PM
https://i.imgur.com/uExTJNI.jpg

https://i.imgur.com/tGELHVm.jpg

https://i.imgur.com/pzjlmAE.jpg

https://i.imgur.com/J94Zh7k.jpg

https://i.imgur.com/cHMl1MF.jpg

https://i.imgur.com/YpVRSpf.jpg

https://i.imgur.com/F1y6SXw.jpg

Aaronhl
05-28-2022, 02:42 PM
Its funny how only a couple of those pictures showing a before and after dont really capture how much of a marathon it is painting
And I can only picture the A LOT MORE work I have to finish the boat and forget how much work I've already put into it, I have to look back at the pictures myself to realize how far it has come, I think it's ugly now with al the repairs showing but last year it was even worse !!

tnelsmn
05-28-2022, 03:24 PM
Glad to see progress being made! Keep on after it.

LakeFever
05-28-2022, 04:53 PM
Lookin good and i agree the gel process is a ton of work. Sanding prep is slow and painful

Aaronhl
07-11-2022, 04:08 PM
Update
Since I started gelcoating the Virage last fall I have been using a HVLP gun, had to thin each cup and could only spray about 300ml at a time, so it took a long time to put multiple coats on, if the gelcoat in the gun didnt harden first!! And because I thinned the gelcoat (wouldnt come outta the hvlp gun without thinning) there was no way to hide the gray primer.
I wish I bought a DUMP GUN from day one, it's like shooting gelcoat outta a fire hose 1qt at a time, Today was the first attempt at spraying with the dump gun...I was able to put so much down without waste and best of all no thinning so it hid the gray primer after a few coats. What a waste of time messing with the HVLP guns !!
So here is an update on the Virage after spraying red gelcoat on the top deck, will need to re-sand the whole deck and sides and then put down another coat or two of red since the bottom half is a slightly different color as that section has been thinned
After a little bit I was able to get a process down for spraying and cleaning the gun because I didnt clean it well the first time... it was blowing chunks of slightly hardened gelcoat, my next application will be nice and smooth
Here are the pics:

https://i.imgur.com/qbYhcvS.jpg

https://i.imgur.com/gMjATZ1.jpg

https://i.imgur.com/MrNs90k.jpg

https://i.imgur.com/duy2tKK.jpg

https://i.imgur.com/WOjMa1N.jpg

https://i.imgur.com/G0cvHYl.jpg

Aaronhl
07-11-2022, 04:13 PM
And check out my new lower unit I refurbished n coned over the winter and just put on the engine

https://i.imgur.com/M6QpMOL.jpg

LakeFever
07-11-2022, 04:52 PM
Wow its really shaping up nice! Looks great man

Aaronhl
09-06-2022, 09:25 PM
Finally got all the gelcoat put on except for the transition on the splashwell
The red gelcoat I sprayed on the transom last year was a different color than what the supplier had this year, it's actually a brighter red gelcoat now, I like it better than the old red version the supplier had, the dump gun I bought makes spraying so easy and less messy using the quart paper cups
I resprayed the top and sides red again because the first coat i sprayed a couple months ago was more of a primer coat (and to learn)
So I rigged up two air hoses using a Y-fitting off the compressor, hung one from the tent and the other kept outside the boat...it was pretty easy to spray the inside and outside at the same time, just used a ladder to hop over the transom to get in an out to refill the dump gun

ok so i am sick of sanding, I started to wet sand parts of the red and it will be a chore, Hopefully I can sand and polish a few areas before winter including the rub rail and dashboard area... so I can put the rub rail on and mount the steering/controls... so atleast I can get on the water and worry about wet sanding/polishing the rest later

Because of the difference in red color I may fade in some black gelcoat (with red metal flake) over the two colors as they meet on the splashwell and transom, I'll be doing that within the next few weeks before the weather gets too cold

let me know what you think


https://i.imgur.com/H8Kz8kZ.jpg

https://i.imgur.com/YKxOnEi.jpg

https://i.imgur.com/XNNw2zT.jpg

https://i.imgur.com/9uuqV8T.jpg

https://i.imgur.com/gjmEOJU.jpg

https://i.imgur.com/MV0ADlF.jpg

https://i.imgur.com/8huMnvd.jpg

https://i.imgur.com/v5MbL6f.jpg
https://imgur.com/H8Kz8kZ

LakeFever
09-07-2022, 05:37 AM
Lookin great! I too prefer the brighter red it really pops

Aaronhl
09-11-2022, 08:48 PM
Best I could do to match the previous gelcoat on the transom to the newer, high quality red...was trying to add metal flake and or some black gradient, went with something more simple.....the two reds kinda have a nice effect and "bloodspatter" looks better than I thought it would,,,next boat will be sprayed as a bare hull haha :)

https://i.imgur.com/7AvXsik.jpg

https://i.imgur.com/c4tLjim.jpg

https://i.imgur.com/DFetMNw.jpg

Aaronhl
09-11-2022, 08:51 PM
Anyone want to help me wet sand :D

Turtleherder
09-16-2022, 11:43 AM
Don’t know how much you want to spend but that deleted splash well area looks like a good candidate for some SeaDek. Maybe a custom “Hydrostream” or “Virage” logo.

turboeddie
09-16-2022, 05:35 PM
510039From one Hydrastream owner to another, message me here on the site with a phone# and I will help out for a day sanding. I’m here in CT for 2 more weeks before heading home to FL. One of the best thread I have seen ever! Bravo!

turboeddie
09-16-2022, 05:38 PM
510040Old boat

turboeddie
09-16-2022, 05:43 PM
510041 New dream boat

tnelsmn
09-18-2022, 10:10 AM
Looks great man! I found I was able to get away with dry sanding the gel for the first few steps, and with a much more aggressive paper than I thought I could. I started at 220 dry then 400 dry and switched to wet at 600. It's all in what the paper can handle. I feel like the colored gel I sprayed sanded much easier vs the clear gel. Maybe try a small area first with some 400 and go from there.

Aaronhl
09-19-2022, 08:58 AM
510039From one Hydrastream owner to another, message me here on the site with a phone# and I will help out for a day sanding. I’m here in CT for 2 more weeks before heading home to FL. One of the best thread I have seen ever! Bravo!

Really appreciate the feedback and offer to help. With the limited sun after work it will be hard to set a time to sand

Aaronhl
09-19-2022, 09:02 AM
Looks great man! I found I was able to get away with dry sanding the gel for the first few steps, and with a much more aggressive paper than I thought I could. I started at 220 dry then 400 dry and switched to wet at 600. It's all in what the paper can handle. I feel like the colored gel I sprayed sanded much easier vs the clear gel. Maybe try a small area first with some 400 and go from there.

Good info maybe I will try a spot at 220 dry to see how it goes, I have the 3M paper I got from the auto supply for my 6" air palm sander, I get what you are saying about quality fo the paper because the 3M paper can flex, Ive got some ebay paper that cracks when you bend it, and if the edges wear/tear on any paper that can lead to scratches, the 3M holds up better on the edges

turboeddie
09-19-2022, 09:05 AM
OK, good luck with the project. ill be back in CT next summer if you need some help. my boat was a Vegas xt skier. loved that boat.510185

tnelsmn
09-19-2022, 09:19 AM
Good info maybe I will try a spot at 220 dry to see how it goes, I have the 3M paper I got from the auto supply for my 6" air palm sander, I get what you are saying about quality fo the paper because the 3M paper can flex, Ive got some ebay paper that cracks when you bend it, and if the edges wear/tear on any paper that can lead to scratches, the 3M holds up better on the edges

I should add that you don't want to take all of the orange peel out with the 220 if you go that route. I removed probably 80-90% with 220, that way I was able to get the 220 scratches out with the 400 etc. without removing excess gel.

3M makes some awesome paper, thats what I used with all my finishing.

Aaronhl
09-19-2022, 09:24 AM
I should add that you don't want to take all of the orange peel out with the 220 if you go that route. I removed probably 80-90% with 220, that way I was able to get the 220 scratches out with the 400 etc. without removing excess gel.

3M makes some awesome paper, thats what I used with all my finishing.

Understood that makes sense to me thank you for the help atleast I think I am on a good track now, finishing takes a lotta work

Aaronhl
09-27-2022, 09:28 PM
I should add that you don't want to take all of the orange peel out with the 220 if you go that route. I removed probably 80-90% with 220, that way I was able to get the 220 scratches out with the 400 etc. without removing excess gel.

3M makes some awesome paper, thats what I used with all my finishing.

It is simple but i think that's where i was messing up, i tried a few test spots going down to a low grit, I was taking ALL the orange peel out with the low grit !! I have since started on some areas with 220 dry and leaving some orange peel like you said, then I can go over everything with 400. I am even comfortable going down to 120 dry in some of the very heavy peel areas knowing I can back out with 220 +......Ideally I want 400 wet to take out all the remaining peel and then I can go up to 600 wet -> 800 wet

Here is what I have so far, I actually resprayed the splash well and transom, I didnt like how the last gradient turned out as I was sanding so I made a hard line around the jack plate and taped around the transom eyes. Best I could do with the different gelcoat colors


Let me know what you guys think

https://i.imgur.com/gkheFim.jpg

https://i.imgur.com/rP0nF7B.jpg

https://i.imgur.com/C4T3NuV.jpg

https://i.imgur.com/KkWGGTX.jpg

https://i.imgur.com/TAUGtNH.jpg

Aaronhl
11-12-2022, 08:08 PM
The warm weather this late into November helped get some stuff done before winter...
So took pretty much all summer to paint the boat and start rigging it like putting the rub rail on, power steering
Not quite ready to run, will get the seats and gas tank done this winter and by spring I should be able to test drive (before I finish everything, like the gelcoat finishing and put the carpet in, etc)

The process I used to polish the gelcoat was actually more sanding DRY than wet, I would take off most of the orange peel with 220 dry changing discs often and then step up to 400 grit dry to remove the rest of the orange peel, the key is to wipe the surface with a towel so the orange peel/areas that still need sanding appear, very hard to sand the peel out with dust on the surface or even water if wet sanding, then a final step of 800 wet before wax and polish

My dad came over today so we bleed the hydraulic steering and I parked our boats in the back yard to get ready for shinkwrapping

Should be back in this thread next year :D

https://i.imgur.com/k95v4hj.jpg

https://i.imgur.com/Oaemfp2.jpg

https://i.imgur.com/Ufgx1tm.jpg

https://i.imgur.com/kQ9GEDr.jpg

https://i.imgur.com/DYXSI37.jpg

tnelsmn
11-19-2022, 03:12 PM
Looks great!

turboeddie
11-23-2022, 01:45 PM
great thread, great project! it will be a fun boat for the ct river and other lakes. I had a 20' Vegas xt skier and loved it. hope to see it next summer when I am in ct. have move up to....512625

Aaronhl
11-23-2022, 03:35 PM
great thread, great project! it will be a fun boat for the ct river and other lakes. I had a 20' Vegas xt skier and loved it. hope to see it next summer when I am in ct. have move up to....512625

Yea it should be at the CTRR next year !! Well seeya there

rgsauger
11-27-2022, 11:34 PM
That turned out sweeeeet! Great job! You should be proud of your hard work!

Meatbasher
12-05-2022, 01:42 AM
What a great looking boat. Such a unique design.

Couple questions for you:

Where did you get the all black rubrail?

Why make the splash well flat? Sorry if this is a dumb question. I just have never seen that done before.

Any idea how much that motor weighs? Just curious as I’m about to repower. I rebuilt my transome a few years back and will be adding a jack plate so I’m always curious to see how much people are hanging off the back verses how they built the transom.

Cheers!

Aaronhl
12-05-2022, 12:06 PM
What a great looking boat. Such a unique design.

Couple questions for you:

Where did you get the all black rubrail?

Why make the splash well flat? Sorry if this is a dumb question. I just have never seen that done before.

Any idea how much that motor weighs? Just curious as I’m about to repower. I rebuilt my transome a few years back and will be adding a jack plate so I’m always curious to see how much people are hanging off the back verses how they built the transom.

Cheers!

Yes the Virage doesnt look like your typical boat, looks different than many of the other Hydrostreams, most Hydrostreams models were pretty unqiue looking though which I think is why many people like them

The Virage hull seam is different from other Hydrostreams, it uses a "shoebox" style instead of a flanged seam,
I looked into so many rub rail variations, changed my mind many times
I hope to never have to put another rub rail on, it was probably one of the most challenging parts of restoring the boat, because it is a RIGID...it's like straighten out a spring and mostly impossible to do without a second person to unwind it as you screw it on...atleast thats how ill try if there is a next time, maybe it will be a little easier...

Finally chose this model rub rail, seems like it is the most similar to the OEM rub rail, except for not being aluminum, metal rub rails are hard to find, the OEM rub rail my Virage came with was in rough shape so I didnt want to reuse it, I think it looks pretty good and I was able to keep the colors to mostly red / black, plan to get some black gauges to match all the other black accessories



R1238 Rigid Rubrail (takes F98175 Flexible Insert)


SKU: 01238RL0732-056GI


Color: Black 56' coil



F98175 Flexible Insert


SKU: 98175DD0732-055GI


Color: Dull Black 55' Coil



CAPECR-2 Plastic End Cap


SKU: CAPECR2


Color: Black

As far as the splashwell, I flattened it so I can add knee supports on the inside of the transom, its kinda like a 3 point system where you have one piece of wood connected to the transom, floor, and splashwell to make it more durable hanging a 12" bracket off the back, should work in theory well see how my work holds up on the water...
I made the splashwell flat but I wish I made a small cut out (like I've seen on other Virages) because the control cables bend when trimming the engine all the way up with the jackplate all the way down, I like to have full movement in all directions without having to worry about the connections, Ill look at that more in the spring...

Motor doesnt weight much maybe about 450 lbs???

Meatbasher
12-05-2022, 09:50 PM
Thanks much for the specific info. I checked out that site and they seem to have the most options I’ve seen. Not too pricey like others.

My rubrail is garbage but I’ve been holding on to it just in case. It at least fits the shape of my boat. I was wondering how the heck you could install such a thing if it was coiled up when I was pulling mine off.

The splashwell on yours looks great. My boat has one and I’m toying with the idea of chopping most of it out and just leaving a shallow well. I have had abrupt shut downs and water wash over the transom since my boat is a tunnel and has a really low rise.

Thanks again for the info and great write up. Really curious how it rides for ya when you are finished.

Aaronhl
09-03-2023, 08:24 AM
Back for seems like an annual update,
Finally got the Virage on the water yesterday, here are some pictures of the work I did this year and then for the on the water pics in a post below
Still have some work to do like sanding the polishing the remaining gelcoat, put carpet in and setup the engine a little more

https://i.imgur.com/CGepN1E.jpg

https://i.imgur.com/I6n6DnK.jpg

https://i.imgur.com/gM3V3K0.jpg

https://i.imgur.com/dCxKzIs.jpg

https://i.imgur.com/cICAqfO.jpg

https://i.imgur.com/jzflsw2.jpg

Aaronhl
09-03-2023, 08:27 AM
Some of the rigging is temporary like the gas pedal floor piece because I wanted to make sure that it was in the right spot, also I used a 6" air sander to sand the interior gelcoat, the paper you see on the floor is only for the small spots the air sander could not reach...I will also add pics of the gas tank/battery setup and also behind the dashboard as all those gauges and wires took a bit to organize

https://i.imgur.com/54ka3st.jpg

https://i.imgur.com/2zlBJjk.jpg

https://i.imgur.com/gDDcEDy.jpg

https://i.imgur.com/oYHgpwb.jpg

https://i.imgur.com/7HJWUjN.jpg

https://i.imgur.com/ZgtAFBO.jpg

https://i.imgur.com/DJkcFnu.jpg

https://i.imgur.com/vrGA0g4.jpg

Aaronhl
09-03-2023, 08:35 AM
saved

Aaronhl
09-03-2023, 08:37 AM
https://i.imgur.com/UEqKWTC.jpg

https://i.imgur.com/SqKMIOL.jpg

https://i.imgur.com/4cYoexU.jpg

https://i.imgur.com/HJbhTk7.jpg

https://i.imgur.com/YiglNS0.jpg

https://i.imgur.com/3oeq5af.jpg

https://i.imgur.com/phKQtX4.jpg

https://i.imgur.com/G9Ri54I.jpg

https://i.imgur.com/Z3IaEi8.jpg

LakeFever
09-03-2023, 08:53 AM
Awesome! Looks great, thanks for updating its so satisfying to follow a build thread through to the end. It puts a big smile on my face im sure you must be amped too

62 bugzilla
09-12-2023, 11:13 AM
Great project and very well done !! I would be very proud of a project finished up as well as this one. Can't wait to see it with final cut and buff it's going to look incredible!!