1978 Boler Complete Restoration / Rebuild

[Nelmes]

Thanks. Paint was my favorite step, it went from looking like a beater to looking new instantly

[GMike A]

Really starting to get there Slav. Lots of good info. Cooler weather heading my way now and time to roll up my sleeves and get back to work.
Mike

[slavandheather]

Originally Posted by Spanke

Slav

Not sure what type of paint you are going to use.

A word a caution, if you are using Interlux Brightsides, they do not recommend using as HVLP sprayer to apply the paint. Use a regular sprayer or Roll & Tip.

He's a link to the Interlux forum that will provide a wealth of information on their paint. Topsides - Yachtpaintforum.com - Page 1

Can't wait to see your results.

I'm in the middle of fiberglass repair and hope to be able to get mine painted before it gets too cold. Gonna Roll & Tip!

Spanke

Hi David,

Thanks so much for the tips! I am thinking of Brightside on the top and I have the bottom color from a marine paint manufacturer from Massachusetts. I am quite certain that I'll do roll & tip as well, especially living in a condo.

I was hoping to be able to paint before the winter, but probably won't happen. Still have a good bit of work.

Slav

[slavandheather]

Originally Posted by Nelmes

Thanks. Paint was my favorite step, it went from looking like a beater to looking new instantly

I know what you mean! I keep envisioning ours painted so it looks new and not like an old turd bucket. Really wanted to get that done by the end of fall, but probably won't happen till spring. Maybe I'll prime it this winter so at least it will look clean on the outside.

Slav

[slavandheather]

Originally Posted by GMike A

Really starting to get there Slav. Lots of good info. Cooler weather heading my way now and time to roll up my sleeves and get back to work.
Mike

Right on Mike, looking forward to your updates!

Slav

[slavandheather]

I can't believe that the last time I worked on our Boler was back in September of last year. We had some transitions/changes and unfortunately the little camper had to be forgotten.

But a couple days ago I was finally able to start it up again...and it feels really good! I got going with patching the rivet holes from the inside with FG mat - most are now patched and we will be staying away from any rivets.

I decided to also put another layer of FG mat around the belly band just to make things stronger (picture below). Don't want the egg to bust in half when I remove the aluminum band for refurbishing!

Here is to getting back to it!

Slav

[slavandheather]

The original windows were in poor state and we wanted to go with something more modern so we got Hehr windows directly from Scamp. Of course not only do they have radius corners but they're smaller overall. Here is a pic of the main side window opening:

And here is what putting in the new window looks like. Shows you that not only do I have to build up the corners but a strip on one of the sides:

I spent part of yesterday and today building up the corners and side in the FIRST side window. It was a lot of work having to tape up wax-paper-lined cardboard and building up the layers from the inside. The issue with that was that the FG wants to fall forward due to a slight angle of the walls, so that took more wax paper and cardboard. In the end it was a lot of work for little progress. And it mostly looks like poop right now ...will take more FG and a some body filler and of course a lot of elbow grease to make it look good. I hope...

For the other windows I think I'll use the scrap FG fragment I have and maybe that will be better.

[D White]

If you would tape or screw wax paper covered cardboard on the outside following the natural curvature of the wall, it would stop the droopy problem....fiberglass Dave

[slavandheather]

Originally Posted by D White

If you would tape or screw wax paper covered cardboard on the outside following the natural curvature of the wall, it would stop the droopy problem....fiberglass Dave

Hi Dave,

Thanks, that's exactly what I did and had to do the same on the inside. The wall has some waviness so it was a pain and will be more work to make it look good.

Slav

[Nelmes]

I used hardboard covered in wax paper. The hardboard was cheap, flexible enough to follow the curve of the trailer and left a smooth finish. Just screwed it on.

[slavandheather]

Originally Posted by Nelmes

I used hardboard covered in wax paper. The hardboard was cheap, flexible enough to follow the curve of the trailer and left a smooth finish. Just screwed it on.

The hardboard sounds pretty good, may try that with the other side. Thanks.

[Timber Wolf]

It is going to look pretty awesome with those new windows, and will be awesome with your fiberglass fixes/reinforcements. I am going to have to learn about FG one of these days.

[slavandheather]

Originally Posted by Timber Wolf

It is going to look pretty awesome with those new windows, and will be awesome with your fiberglass fixes/reinforcements. I am going to have to learn about FG one of these days.

Thanks! FG is relatively easy, just messy and very stinky (use a respirator). Big pieces are more challenging.

[slavandheather]

Originally Posted by Nelmes

I used hardboard covered in wax paper. The hardboard was cheap, flexible enough to follow the curve of the trailer and left a smooth finish. Just screwed it on.

Hey Chris, did you first screw in the exterior board, then apply the fresh FG layers from the inside and then screw in the interior board? That seems to make sense to me, but let me know if I'm forgetting something. I am feeling a bit discouraged with the way the first window went and may just opt to go with using spare FG like I did in post #114.

Thanks for your help.

Slav

[D White]

Originally Posted by slavandheather

The original windows were in poor state and we wanted to go with something more modern so we got Hehr windows directly from Scamp. Of course not only do they have radius corners but they're smaller overall. Here is a pic of the main side window opening:

Attachment 72131

And here is what putting in the new window looks like. Shows you that not only do I have to build up the corners but a strip on one of the sides:

Attachment 72132

Attachment 72133

I spent part of yesterday and today building up the corners and side in the FIRST side window. It was a lot of work having to tape up wax-paper-lined cardboard and building up the layers from the inside. The issue with that was that the FG wants to fall forward due to a slight angle of the walls, so that took more wax paper and cardboard. In the end it was a lot of work for little progress. And it mostly looks like poop right now ...will take more FG and a some body filler and of course a lot of elbow grease to make it look good. I hope...

Attachment 72134

For the other windows I think I'll use the scrap FG fragment I have and maybe that will be better.

Just sand that patch with 80 grit real good and put some filler (bondo) on it and you will be amazed how easy it smooths up...fiberglass Dave

[slavandheather]

Originally Posted by D White

Just sand that patch with 80 grit real good and put some filler (bondo) on it and you will be amazed how easy it smooths up...fiberglass Dave

Yes, will do, thanks Dave!

[Nelmes]

I screwed hardboard on the outside matching the profile to give it shape. Then added either bondo or gelcoat (bondo is not the best for this as in bigger patches it can crack after a while). Then I added a layer of fiberglass on the inside. Let it dry, then another and so on. I didn't use a form on the inside, as the fiberglass took the shape of the outer mold.

[slavandheather]

Originally Posted by Nelmes

I screwed hardboard on the outside matching the profile to give it shape. Then added either bondo or gelcoat (bondo is not the best for this as in bigger patches it can crack after a while). Then I added a layer of fiberglass on the inside. Let it dry, then another and so on. I didn't use a form on the inside, as the fiberglass took the shape of the outer mold.

Sounds good, thanks.

[Nelmes]

A little rain and wind yesterday wasn't enough to give me confidence, so I pulled out the hose. The product fixed it. It was a leak that only appeared with heavy storms.

[slavandheather]

Originally Posted by Nelmes

A little rain and wind yesterday wasn't enough to give me confidence, so I pulled out the hose. The product fixed it. It was a leak that only appeared with heavy storms.

I think I missed you mentioning where this leak was. Was it around the front window?