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Dargo
07-29-2019, 05:02 PM
After many years of sitting under various tarps and covers, I have dug out the Rally Sport and am attempting to get it up and running. I began this project 8 or 9 years ago. A couple of daughters and a divorce forced it to be put on the back burner. So, there it sat. It has been cared for over the years and not just left to rot but, time has taken its toll on a few items. I'm slowly wrapping my head around where and what I left off on. I absolutely love the boat and could never bring myself to put it up for sale. It has an '87 Johnson V8 on the back that refuses to cooperate. I'm no engine guy so it's a challenge in that department. Hopefully there will be pics on the water some day!
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Any chance this is just cracked filler from the nose cone??
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Is this stator still operational with the windings looking like this?
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tux974
07-30-2019, 04:50 AM
Boat looks good!
Yes, I say thats the filler/bondo cracking. May have gotten water behind it.
Probably with some TLC and a little work it will start right up.......:thumbsup:

Dargo
07-30-2019, 11:18 AM
She needs some love but it'll get there! I need to pull the lower and grind a bit. I hope you're right! Still having a hell of a time getting it to idle. Does nothing but want to rev to the moon as soon as it fires. No change no matter what I adjust.

tnelsmn
08-03-2019, 06:52 PM
Thats a sweet looking boat! Looking forward to seeing on the water!

race30
08-04-2019, 08:12 AM
I have the same boat with a 300XS that has been "restored"
it's worth it!!

Dargo
08-04-2019, 11:00 AM
Thats a sweet looking boat! Looking forward to seeing on the water!

Thanks, me too!

Dargo
08-04-2019, 11:02 AM
I have the same boat with a 300XS that has been "restored"
it's worth it!!

I think I've seen your boat before...very nice! Any idea if they used any coring in these hulls?

Radazzle
08-04-2019, 05:39 PM
Yes, they used balsa Core in the hull bottom and probably sides. 3/8 or 1/2 inch thick.
Not sure about the deck/cap.

tux974
08-05-2019, 05:01 AM
Yes, they used balsa Core in the hull bottom and probably sides. 3/8 or 1/2 inch thick.
Not sure about the deck/cap.

Yes, my RS deck has balsa.
I find they are built a bit heavy but run well in/over chop.

Dargo
08-05-2019, 12:00 PM
Oh ok. I figured they probably were cored somehow. My sides aren't cored and I don't believe my deck is either.

Dargo
09-09-2019, 03:35 PM
Been a little slow going lately. Reworked my fuel system and finally managed to get a compression test done. Was about 102-109 on all cylinders so looks like all is well in that department still. That was on a cold motor. Not up and running quite yet. Cleaned up the stator and sprayed that. New flywheel key too as the old one gave up the ghost. Pumped out about 30 gallons of old fuel. The inside of the tank looks brand new so I was happy to see that. Fuel sender looked good still after cleaning that up. Hopefully it's still serviceable. Making progress, just not as quickly as I'd hoped!

99fxst99
09-09-2019, 04:38 PM
I have the same boat with a 300XS that has been "restored"
it's worth it!!
What does yours run and what prop are you running?
I have one with a 300 Promax.

race30
09-09-2019, 06:42 PM
What does yours run and what prop are you running?
I have one with a 300 Promax.

86 so far at 6000 rpm
havent gotten a flat enough runway yet!
i have vid of it going 95 with a 27p prop

99fxst99
09-10-2019, 12:52 PM
86 so far at 6000 rpm
havent gotten a flat enough runway yet!
i have vid of it going 95 with a 27p prop

Thanks,
That's pretty good. I am still in the 70s, but my motor is high hrs/tired.
Sorry Dargo, didn't mean to hijack your thread!

Dargo
09-11-2019, 01:00 PM
Thanks,
That's pretty good. I am still in the 70s, but my motor is high hrs/tired.
Sorry Dargo, didn't mean to hijack your thread!

No worries! Any conversation about these boats is good with me!

Dargo
11-24-2019, 04:38 PM
Update time...

Now that winter has set in, deer season is over, and snow is on the ground, I'm back to boat work. Got the fuel system wrapped up. Added a screen-type prefilter and a water separating filter after the pump. Moved my fuel pressure gauge onto the extra outlet on the regulator. Cowl and pans off the motor and pulled the lower unit so I can get the old filler off and replaced with new. Good news was the case isn't cracked. Just the filler let go. Also, found that the nosecone is tack welded on. Was happy to see that. Last but not least, I stripped all the hardware and windshield off the hull and started the never ending process of wet sanding the cap. What a pain in the a**!!! Just time consuming I guess. Lots of paper and lots of Coors Light! I started with 800 grit hoping that would be enough but I wasn't getting all the oxidation off and it wasn't completely flattening the orange peel that had developed on the metal flake portion. Went down to 600 and am making much better progress. Might need to step to 400 for a couple stubborn areas but I'm trying to avoid that. From there I'll go through 800,100, and 1500. Then, 3m super duty rubbing compound, Finesse-it II, and fleetwax. Going to be a busy winter!

I do have a question for anyone that's still reading! After I have knocked down the texture or orange peel over the flake, I can see some porosity in the gelcoat. They look almost like tiny cracks here and there. I know that this portion of the boat will never be perfect as the flake has some silver showing so I assume there is some amount that has made it through the clear. Maybe the pitting and tiny cracks are from that. I guess I'm wondering how I address this. Or if there is anything I can do. Will they sand out if I keep going or just leave them and chalk it up to a 30+ year old neglected gelcoat? More to come and I'll try to post up some pictures.

tux974
11-25-2019, 05:55 AM
I have a similar situation small little spidering on the forward section of my deck. It is only directly above the forward bulkhead where it attaches to the deck.
It is minimal and in a straight line i was told by a glass guy its post cure from lower matting/attachment. Nothing else on the rest of the deck and hull! There is no sign at all of weakness, cracking or water intrusion so I have decided to leave it alone since it is very minimal.
Boat is wrapped or I would send you some detailed pictures.

This is my RS. I cut down my windshield approx 3" and removed the lifeline.
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Dargo
11-25-2019, 08:10 PM
Ooof that is a sweet machine! I'll try to get some pictures this weekend. I won't be back to the boat until then. I guess I assumed it was just the clear part of the metal flake stripe that had been damaged by the elements over the years. Might be best to just let it be as well.

Dargo
12-01-2019, 02:03 AM
Progress pics...got the 600 grit done over the whole cap. Ready to move to 800. Lots of work ahead of me!453725

Dargo
12-01-2019, 02:05 AM
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Dargo
12-01-2019, 02:07 AM
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whipper
12-01-2019, 03:04 AM
She needs some love but it'll get there! I need to pull the lower and grind a bit. I hope you're right! Still having a hell of a time getting it to idle. Does nothing but want to rev to the moon as soon as it fires. No change no matter what I adjust.


Just Grind it alot not a little on that gearcase. Take it right down to Aluminum every were and redo it is the way to go. Kinda fun day project but the results will be way way better and longer lasting than just getting into those cracks. :cheers: Re Shaping inst as hard as ya think just smooth out every were it needs to be youll see were and maybe even throw your own trick or two into the shape. Doesn't hurt nothing. There are enough pictures and threads on how to do this on hear you'll be able to figure it out easy peezy.

whipper
12-01-2019, 03:10 AM
Oh ya great thread keep it going you got a great project a head of you!! When your done it will be so so worth every second spent doing it with such an iconic hull!:cheers:

tux974
12-01-2019, 05:31 AM
Progress pics...got the 600 grit done over the whole cap. Ready to move to 800. Lots of work ahead of me!453725

Coming along nicely!
Oh yes, anytime you get into a project like that it ALWAYS becomes LOTS more work then anticipated!
It should be worth in the end though.....:thumbsup:
BTW, just buy a few extra of those silver cans on the deck......;):thumbsup:

Dargo
12-03-2019, 09:23 AM
Just Grind it alot not a little on that gearcase. Take it right down to Aluminum every were and redo it is the way to go. Kinda fun day project but the results will be way way better and longer lasting than just getting into those cracks. :cheers: Re Shaping inst as hard as ya think just smooth out every were it needs to be youll see were and maybe even throw your own trick or two into the shape. Doesn't hurt nothing. There are enough pictures and threads on how to do this on hear you'll be able to figure it out easy peezy.

That was my thoughts too. I pulled the loose chunks off and thought about just filling it as is but there was a part of me that kept saying, you know better! Lol. Any recommendations as to what is best as a filler? I was looking at the Evercoat Metal to Metal. Not real sure what's best to use.

Dargo
12-03-2019, 09:27 AM
Thanks for the compliments! It's really been worth the work so far. The boat has never looked this good since I've owned it. Nice to be able to address some of the small scratches here and there. It'll never be perfect but I'm doing my best to make it as good as I'm able right now. I'd love to tear it completely down someday, fill the spider cracks from what looks like piss poor docking, fair everything, and paint the hull. Maybe someday! For now, I need a clean runner.

Dargo
12-03-2019, 09:29 AM
Coming along nicely!
Oh yes, anytime you get into a project like that it ALWAYS becomes LOTS more work then anticipated!
It should be worth in the end though.....:thumbsup:
BTW, just buy a few extra of those silver cans on the deck......;):thumbsup:

I think I'm using equal parts sandpaper to Coors Light!

whipper
12-04-2019, 07:38 AM
That was my thoughts too. I pulled the loose chunks off and thought about just filling it as is but there was a part of me that kept saying, you know better! Lol. Any recommendations as to what is best as a filler? I was looking at the Evercoat Metal to Metal. Not real sure what's best to use.

I used short stran kiddy hair and lasted for years without a problem. That stuff hardens like steel! Its fast acting so ya gota smooth it out fast because sanding it is a bitch its so hard quickly.