Resurrecting a 1652 MonArk

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lbursell
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Resurrecting a 1652 MonArk

Post by lbursell »

Progress is being made and it feels good. Time to get some bunks on. This is one of the areas where I'm wanting to stretch the envelope a little bit. Instead of using wood for the bunks, I gonna try out the composite decking material. A lot of people have said that the composite decking is too flexible. I think that I've thought this through pretty well and I don't see the problem. I'll keep an eye on the bunks and report back on how they're doing in a year or so. With my slow rate of progress, I just hope the boat is in the water within a year.
One thing I want to point out is that during this phase of the project I was working on multiple things concurrently. Bunks, lights, winch post and trailer jack were all being worked on at the same time. While paint or glue was drying on one thing, I would be working on something else. To keep the thread readable, though, I've separated each sub-project into its own category. So, you may see guide-ons with lights already mounted in the bunks section and then later on you may be reading the section about lights, but the pictures don't show that the bunks have been mounted yet. I'm doing it this way to try to keep the thread from being confusing.

OK, before I started this project, the bunks were four foot long 2x4's that only extended a little past the axle on two bunk brackets. And the front 18 inches or so of the bunks were unsupported.
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So, I went with two 6 foot long sections of the composite material in a 2x6 configuration. I later decided that the 6 foot length was a little too long, so I cut off 4 inches, to make them 5 feet 8 inches. I'm a little concerned right now that this was a mistake, but I'm committed now. We'll just have to see how it comes out. The new bunks will be supported from all three of the trailer crossbars. In other words, three bunk brackets supporting the bunks in front, middle and back. My thinking is that this will defeat the flexibility issue.
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First thing is to establish the height of the bunk brackets. I used this template I had put together when I built a wheelchair ramp for the mom-in-law. I'm not even sure what the actual height is; It just happens to be the right height so that all the bunks will sit clear of the fenders.
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Bracket heights are set. The first thing you will notice about the composite material is the grooves that run the length of the board. To be sure of stability, I decided I didn't want that side to be mounted directly on the bunk brackets, so that automatically became the top side.
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To locate the position of the mounting holes, establish the middle of the board.
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Draw the center-line down the length of the board.
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Lay the board, with the center-line down, on the bunk brackets. Then, from underneath, mark the location of your mounting holes.
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Drill out your mounting holes.
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Use a hole saw to carve out the grooved section so that a washer will fit in that space.
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Only use the hole saw to cut out just to the bottom of the groove's trough.
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Then, use the wood chisel to remove the little arced sections to flatten out the bottom part of the hole.
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One of the little arcs removed.
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Use the wood chisel to smooth out the bottom of the mounting hole. This composite material is very easy to work with.
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Bolt and washer ready to go into the mounting hole.
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The bolt head is below the top of grooved surface.
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Bunks laid out on top of the brackets. So far, so good.
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Resurrecting A 1652 MonArk
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imgonnamissher
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Resurrecting a 1652 MonArk

Post by imgonnamissher »

Great job so far. I to am hoping to make my trailer and boat the same color, but haven't decided whether to spent he money to match or just paint it black. Can't wait to see progresss on the boat. You're doing great. =D>
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lbursell
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Resurrecting a 1652 MonArk

Post by lbursell »

I got to thinking about the bolt head being covered with carpet and realized that it would probably just turn when I tried to tighten the nut. I didn't want to cut out the carpet to gain access for a wrench, so I decided to give this stuff a try. Its one of those two-part epoxies that you slice off a chunk, then knead it like bread for a minute or so to mix and activate the chemical reaction.
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Applied the epoxy to both sides of the washer, then squeezed down on the bolt head.
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This is the first result and I decided it was crap-ugly. (Even though its gonna be invisible.) Image

Then, I thought some more. Eventually, water is gonna get into those grooves. I don't want the water to be stuck there and stagnate. That will in turn cause the bunk carpet to start rotting. I'm gonna have to make some drains for the water to get out. I don't want anything inside the grooves to impede the flow of the water to the drains, so I want everything around the bolt-head to be as smooth as possible.


So, then I developed myself a little system. First, apply the epoxy only to one side of the washer.
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Then, squeeze the washer down over the hole with your thumbs. See that little dollop of epoxy that squishes through the washer hole?
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From underneath, push the bolt through the washer to clear the epoxy dollop from the center of the washer.
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Remove the dollop and pull the bolt back out. Use the dollop to form a collar around the bolt, just beneath the bolt head.
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Re-insert the bolt through the washer. This time from the topside.
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Squeeze down with you thumbs again, squishing out the excess epoxy from beneath the bolt head.
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Remove the excess epoxy from around the bolt head and use it on the next bolt/washer combination.
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So, those aren't grooves in my bunks anymore. They are now channels to facilitate draining water from my bunk boards. Three holes drilled through the channels at the lower end of the bunk boards creates my drains.
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Notch out the bottom holes in each channel so that every drop of water can get out.
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If you have drains at the lower end of the channels, you need air holes at the upper end to insure that the flow of water is unimpeded.
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Resurrecting A 1652 MonArk
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lbursell
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Resurrecting a 1652 MonArk

Post by lbursell »

Time for a little carpet work on the bunks. I wanted to find a matching blue for the bunk carpet. Checked out the local carpet stores and nobody had what I wanted. The Lowes and Home Depot carpet didn't leave me impressed. Ordering online, I could have gotten the color I wanted, but I couldn't see forty bucks for bits of carpet that will be under a boat 99% of the time. Got this remnant outdoor carpet several years ago, thinking I might use it on the front deck of the boat. Ten bucks for 6 x 7 feet. That was before I found TinBoats and learned what could really be done to a boat. The roll is hooked from laying over a rafter for at least five years. Even though its not blue, the maroon is close enough to red that I can say my trailer is red, white and blue. :)
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This is the adhesive I used. If they ever need a product endorsement, I'm the guy. Works great. Note the test sample in the background.
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Carpet laid out nice and flat. Place the boards for measuring your cuts.
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I masked off the area I wanted to put glue on during this step. Apply the adhesive to the carpet, then apply to that side of the bunk board. Apply the adhesive on the board only on the top of the board that will be in contact with the carpet. Keep the glue out of your water channels.
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After applying the adhesive to both surfaces, wait five minutes, then place the board on the carpet. Remove the masking.
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Appy suitable weight, then give it a couple of hours to cure. Or, in my case, overnight. That Weldwood Contact Cement works good enough that I probably could have finished the job without waiting. But, it was the end of the day and I was tired.
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Resurrecting A 1652 MonArk
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lbursell
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Resurrecting a 1652 MonArk

Post by lbursell »

The next day I uncovered the combined bunk board / carpet assembly and started making preps for the final application of glue. Cut slits in the carpet for the drain holes using a piece of scrap composite to get things lined up.
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As you can see, I didn't allow quite enough space for the fold-over.
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So, on the next piece, I used the scrap composite plus two layers of scrap carpet as spacers. That made it near perfect.
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The most mentally challenging part of this phase is getting the cuts right to allow for folding the carpet around the ends of the bunk boards. Really take your time here, visualizing how each layer will fold around, because once you lay the glued pieces together, they'll be very difficult to pull back apart.
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Applied clear tape to cover the drain holes. I didn't want any glue inside the drain holes. Then painted the adhesive all over the bunk board and covered the carpet.
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Wait five minutes or so, then remove the masking tape.
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Then, start folding the carpet into the adhesive.
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I wanted to get multiple layers of carpet at the lower end of the bunks to provide some cushion for those "just in case" moments.
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Folded over - Almost ready. Note the little gap where I mis-measured in the lower left corner. I just cut another small piece of carpet to plug in to the gap. We'll see how long it holds.
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Reinforced the tag ends with screws and washers.
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I think the results came out pretty good.
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I'm pretty pleased. The red, white and blue goes pretty good together.
Resurrecting A 1652 MonArk
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lbursell
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Resurrecting a 1652 MonArk

Post by lbursell »

Now to back up a little and show the lights assembly and how I put a little more blood into the project. Starting out with the guide-ons.
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Wiring ran through the guide-ons and out the top.
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Guide-ons mounted.
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Lights are also mounted low down at the trailer frame.
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The next problem is that the guide-on pipe wasn't wide enough to accept both of the mounting posts on the trailer lights. So I figured to fabricate a bracket to attach to the guide-on for mounting the trailer lights. Took a simpson strong-tie for rafters and joists.
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Used tin snips to cut off the sections I needed to fab my brackets.
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Took my brackets to the drill press to enlarge the hole to accept the trailer light mounting post.
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There's something that I've known for a long time, but never needed to articulate until I was making these brackets. One of the things that happens when you're drilling through metal is that, just as the drill bit breaks through the far side metal, the bit and the metal bind together. This either causes the drill to torque in your hand or, if your using a drill press, can cause a rather small piece of metal to start spinning at a fairly rapid pace....
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....Resulting in this. That finished my work for that day.
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Last edited by lbursell on 10 Apr 2011, 08:20, edited 1 time in total.
Resurrecting A 1652 MonArk
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lbursell
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Resurrecting a 1652 MonArk

Post by lbursell »

So, after licking my wounds and buying some bigger band-aids, I finished the brackets and mounted them at the top of the guide-ons.
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See the hole in the guide-on for mounting the other side of the light post? What I failed to think through is the fact that both mounting posts need to be grounded to the trailer frame. That fact gave me the blues for about a day and a half trying to get the lights to work properly.
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I wanted something a little more substantial that just running a wire between the mounting posts. So the fix was to take a short length of galvanized metal duct tape and mount the lights with the mounting posts through the holes in the duct tape.
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Hook everything up and suddenly I have trailer lights that do what they're supposed to do.
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You can see the galvanized duct tape on the left side of the light. If anybody's curious, the forward facing red reflectors are for backing up at night.
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Then working on connections at the front end.
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Every connection on the trailer got two coats of liquid tape, then sealed with at least one layer of heat-shrink tubing.
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Final product on the front end.
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Now we're getting towards the end on the trailer. A little more painting and mounting of some hardware. I'm starting to see a light at the end of this tunnel.
Resurrecting A 1652 MonArk
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rmzachar
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Resurrecting a 1652 MonArk

Post by rmzachar »

That looks fantastic!

GaBassin
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Resurrecting a 1652 MonArk

Post by GaBassin »

I cant wait to see the progress of the boat. This is the same boat I have. If I can figure it out I will upload the pictures from my modification. Good luck and enjoy.
1648 Monark Conversion

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fender66
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Resurrecting a 1652 MonArk

Post by fender66 »

Dang.....project looks great. Your injury made things inside of me hurt. Have no idea what that was either...just hurt. :shock: Hope you heal fast.
Peace,

Chris/Fender66´¯`●.¸.¸¸.●´¯`●.¸><((((º>
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lbursell
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Resurrecting a 1652 MonArk

Post by lbursell »

GaBassin wrote:I cant wait to see the progress of the boat. This is the same boat I have. If I can figure it out I will upload the pictures from my modification. Good luck and enjoy.

I would love to see someone else doing the same boat I have. See if great minds really do think alike. 8) Uploading pictures isn't that hard, just time consuming. Getting feedback just motivates you to keep going. Knowing that the photographic evidence of your accomplishments and mistakes is out there for the world to see makes you want to keep on doing it right. And, I'm still having a blast doing this. I'm so close to actually getting started on the boat, it makes my mouth water.
Resurrecting A 1652 MonArk
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lbursell
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Resurrecting a 1652 MonArk

Post by lbursell »

fender66 wrote:Dang.....project looks great. Your injury made things inside of me hurt. Have no idea what that was either...just hurt. :shock: Hope you heal fast.

Thanks for the compliment. The thumb is all healed up. Just real tender and itches constantly. When I first did it, I actually expected it to be broken. The funny/embarrassing thing is... Right before I did it to myself, the thought crossed my mind: "You should probably put those leather gloves back on." :idea: :oops: #-o ](*,) Maybe someday I'll be smart enough to use power tools. [-o<
Resurrecting A 1652 MonArk
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Slowcrank
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Resurrecting a 1652 MonArk

Post by Slowcrank »

I'll have to tell you, I'm really enjoying following you along with your progression. Wish I was there to help... You have been doing a great job. I can't wait to see and read about your experiences with the boat itself. Do you know when your gonna start on it? Or when your gonna start posting again? I'm sure the finger is completely healed by now. LOL Good luck and thanks again for all that you are doing to help everyone out there have a better understanding and "guide" to the How To's of Resurrecting an old classic boat like the "1652" MonArk.

=D> =D> =D> =D> =D> =D> =D> =D> =D>

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Resurrecting a 1652 MonArk

Post by That Robbie Guy »

Woah ... such great attention to detail !

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bulldog
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Resurrecting a 1652 MonArk

Post by bulldog »

Amazing. Everything looks very well thought out and you have a great eye for detail. Great job and thanks for all the pics.