23 ft Hartley Cabin boat repair/rebuild and hull extension

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magoo_za
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23 ft Hartley Cabin boat repair/rebuild and hull extension

Post by magoo_za »

New to the forum, hoping not to screw up and hopefully gain some knowledge.......

I acquired a 23ft Hartley in July 2019. Everything being equal the boat appeared in a reasonable state:
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After initial rigging and repairs, we performed a maiden voyage to only discover a major bearing knock in the starboard side motor. So I changed out to a pair of 115 Evinrude Etec's. boat rigged and launched, tested for leaks 2 weeks on mooring.....
20191019_170440.jpg
This is where my problems began.....

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magoo_za
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Re: 23 ft Hartley Cabin boat repair/rebuild and hull extension

Post by magoo_za »

My story goes on as follows:

Due to the Etec's being 20" and the Mercury's being 25" motors I needed to move the outmount brackets down by 5". This meant that the poorly designed and constructed pod was useless.....

20191104_185612.jpg

I removed the Etec's to inspect and build a replacement pod. On inspection a small delamination was discovered which led to the discovery of a waterlogged, rotten transom..... :help:

20191109_192946.jpg

Deciding to open the deck on the inside, I cut away a portion to discover that the foam and bulkheads were rotten....

20191112_191108.jpg
20191112_191120.jpg

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magoo_za
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Re: 23 ft Hartley Cabin boat repair/rebuild and hull extension

Post by magoo_za »

Some more deconstruction images

20191112_191128.jpg
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20191116_160606.jpg
20191116_160611.jpg
20191116_160617.jpg
20191116_160707.jpg

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Re: 23 ft Hartley Cabin boat repair/rebuild and hull extension

Post by Jeff »

Welcome to the Builders Forum magoo_za!! Sorry for all that you have found so far!!! The guys here will help you get her fixed!!! Jeff

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Re: 23 ft Hartley Cabin boat repair/rebuild and hull extension

Post by piperdown »

Wow! That's a whole lot of sopping wet foam! 8O

Looking forward to seeing the repairs. We all love boat porn! :lol:
Eric (aka, piperdown)

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Re: 23 ft Hartley Cabin boat repair/rebuild and hull extension

Post by Fuzz »

Sounds like you got a trailer and a hull for your money. Tell us a little about the hull, is it a glass hull? And is it a hull that you really like? I ask because this is going to be a ton of work to fix it right.

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magoo_za
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Re: 23 ft Hartley Cabin boat repair/rebuild and hull extension

Post by magoo_za »

Fuzz wrote: Thu Jan 09, 2020 3:26 pm Sounds like you got a trailer and a hull for your money. Tell us a little about the hull, is it a glass hull? And is it a hull that you really like? I ask because this is going to be a ton of work to fix it right.
Wow I did not expect to receive any views let alone replies and interest! thank you all.

The hull is made of fibreglass with interior fittings of plywood. These include the helm station and cabin benches. The hull is approximately 14mm thick adjacent to the keel and tapers of to about 10mm on the chines, with sides approximately 6mm. Seems it was built with woven roving from prints I could identify during the cleanup.

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magoo_za
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Re: 23 ft Hartley Cabin boat repair/rebuild and hull extension

Post by magoo_za »

piperdown wrote: Thu Jan 09, 2020 11:33 am Wow! That's a whole lot of sopping wet foam! 8O

Looking forward to seeing the repairs. We all love boat porn! :lol:
Hi, yes that it a lot......that is however one of 9 similar sized bags removed. All-and-all the underdeck volume of the stripped area should be approximately 4.3m3 of which about 1.2m3 was taken up by the fish hatch. The rebuild will follow the same route with some major modifications to structure.

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Re: 23 ft Hartley Cabin boat repair/rebuild and hull extension

Post by magoo_za »

Ok so my story continues.......

Some more destruction images below. you will notice remnants of bulkheads and no bulkheads, the reason therefore is that the existing bulkheads were 9mm ply (Not sure if it was even marine ply as delamination was visible) tabbed to the hull and screwed to maranti 40x20mm beams. Everything was rotten to the core, even the maranti which is an African hardwood.
20191116_160617.jpg

Some more deconstruction images......

20191124_193725.jpg
20191124_193741.jpg
20191124_193802.jpg

You will notice in the image below that when the original transom was removed that a bow exists in the port side flange of the hull. I assume this was either a scew mold or early premature mold removal.


was
20191130_194901.jpg

I cut the section where the transom was back 65mm to correct the issue and to save myself a lot of grinding out epoxy.

20191216_152015.jpg

From the above image, apart from cleanup, I had a bare canvas to start working.......

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Re: 23 ft Hartley Cabin boat repair/rebuild and hull extension

Post by magoo_za »

From the proposed design image (posted earlier) I selected the following materials for use:

- Core - Lycell (Similar to Divinicell) in two variants, a 10mm and 20mm sheet. Both with a compressive rating of 80kg/m2
- Bulkhead and deck glass is 410 biaxial (Each 20mm bulkhead received two layers a side to a total of 1.5mm a side). By the way I was amazed to see the mechanical effect of the two layers on either side of the foam)
- The hull extension is to be built from 10mm core but with the following arrangements:
  • 1.
Inside of the hull - 5 layers of 900 quadraxial, each corner to be fillited with thickened resin, first covered in a 650 UD tape (130mm wide) and then each side panel to overlap into the floor piece with every second floor panel to overlap onto the sides. I estimate this would make the chines and corners approximately 8mm thick on the inside.

I am planning on placing additional tape in strategic positions from the sides across to the floor/transom to ensure that sufficient mechanical strength is built-up
  • 2.
The plan is to fibreglass the bottom with 3 layers of 900 quadraxial as well.

  • 3.
ISO Polyester resin was selected to do the project. The resin is Loyds of London certified for marine application/construction. Epoxy and Vynilester is EXTREMELY expensive in SA and difficualt to come by seeing I live in a remote town about 400km's from the closest major city.

Any advice on this approach is appreciated

Below image is of the Lycell being used. you will notice that the panels are drilled with 3mm weepholes for resin intrusion as the foam only absorbs on the very outer layer due to its structure.

The below is the base design I did. Bear in mind not all dimensions were known but estimated to about 95% accuracy

Stokstyf float.pdf
(33.95 KiB) Downloaded 58 times

My preliminary cutting list looked as follows:

Stokstyf Cutting List.pdf
(23.22 KiB) Downloaded 42 times
Last edited by magoo_za on Fri Jan 10, 2020 5:20 am, edited 2 times in total.

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