Right after picking up the new boat from a friend in St.Alban's Vermont. A 5 hour drive from my Long Island home without the boat.

9 hour drive home with very frequent stops, tires got warm but was a pretty smooth ride home.

I decided to double up this deck board. It sagged quite a bit with weight on it and I want to be able to walk on the deck. much stiffer and should not cause any problems transfering stress to other framing.

another view of the same

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Using old deck as template on mahogony marine 1/2 inch ply

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The more I looked at the transom the more I knew it had to be replaced

put together a quick sturdy dolly for the motor

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I was able to push a screwdriver all the way through this spot

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Nice new mahogony

treated plank ends with penetrating epoxy/and epoxy filler

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next will be tightening the hull and dealing with a small anount of delamination on the hull

Starting work on the hull

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New gunnel rails

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Every screw tightened and replace if necessary. this noticably stiffened the hull quite a bit. wood srews are used through the hull into the ribs and machine screws with nuts are used plank to plank. had to do this by hand due to the fact that the drill would either snap the screw or not tighten it enough. thats alot of screws.
all the holes where cleaned out and filled with epoxy filler and sanded smooth

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Had to replace part of the keel. scarfed in a piece of white oak

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using interlux Brightside poly paint over epoxy primer, hatteras white
this color was changed to a more pure white....but I found a few cans of the old color at west marine. its not a pure white. has a very light touch of cream color to it. Really nice and perfect for this boat

second coat. sanding between

This has been a tremendous amount of work but worth it. the hull is going to look like new

New ribs?

I agonized over whether or not to change out a few of the questionable ribs

White oak that is green or not kiln dried. better for steam bending

White oak and Max. he likes wood

bending stockall ready for the steamer

these where the worst two or so I thought. these ribs just fell apart when I took the screws out. I was very surprised how bad they really were.

one side

almost done I was able to steam 2 ribs at a time which took an hour so this was a very time consuming job, but I feel alot better about the boat.

Pile of bad ribs I removed

MY PAINT!!

Oh well It needed to be done.

That wasn't so bad

one more finish coat will do it.

paint and new ribs

Next I put back together the motor well. All of the wood here was in good shape and I just cleaned it up a little

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Finally able to use the decking I cut out a few months ago

new deck boards

new deck boards

filling screwholes with plugs cut from the same pieces of wood as the deck

this stain is the same as the original factory stain. same color

stain

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stain

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10-12 coats of varnish followed by 600,800,1200,1500 wet sanding and 3m rubbing and polishing compounds plus many hours and 2 buffers. one didn't make it. I'm not sure I will continue to do this in the future. but it was just too dusty in my work area and this looks really good.

building new 4 pane windshield, old one was beyond repair. using same joinery as original

needs to be scribed to match the crown of the deck

checking fit

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installed some hardware today. buffed the chrome stuff a little bit to make it shine nice.

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just trying the sepia setting on my camera. kinda neat

fitting new deck hatch

fitting lid

stained and ready for varnish

steambending new white oak rails for the front of the deck

attached and ready for plugs

second rail cracked. will try again tomorrow

Finally after 5 tries. I think the oak had dried out too much for bending, not sure but steamed the last one for 2 hours and that seemed to do it

sanded flush

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stain

little varnish

first 2 new frames

first 2 new frames

with new sides

with new sides

with new sides

plugged screw holes and cut the wood for the flip up windows.
This is turning out to be the trickiest joinery of the project, but its turning out very nice and exactly like the original. I need to find new rubber glass retainer and weather stripping

hinges and brackets trial fit

hinges and brackets trial fit

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I debated putting the name plate on the top plank. Grady white did it both ways. it was originally put one down on this boat so thats what I did.

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Was in very good shape. Looked like it had been rebuilt very close to the last time it was run. most of the parts were in "like new" condition.

Looks ok after a long winter sleep


Windshield is just about finished

Dashboard hardware back in place after some cleaning and buffing

Built a bench seat for the back. My first Grady had one of these when I bought it so I added one here. not sure if Grady White installed these or it was added later. anyway I like what it does, storage,seat and a step in and out.

stripping, staining and varnishing the inside of the planking.
not a fun job but will be nicer.

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Ran great handled perfect