1969 Chris Craft Roamer 46 Refit: Strengthening the Salon Roof

While installing the hatch and 1/4″ marine-grade Douglas fir plywood that underlays the FRP skin on the salon roof, I cleaned the old fairing compound off of the cut edge of the original Chris Craft fiberglass. What I found was…disturbing.

The previous weekend, I put in the salon roof plywood.

When putting in the battens, I finally “saw” something that had been obscured by fairing compound.
See the wavy FRP layup?

Catchin’ the wave now?

See the little dude on the surfboard? 😉

What we have here is three layers of fiberglass. The top layer follows the shape of the mold, as does the bottom layer (presumably, so the boss wouldn’t notice what was going on in between).
But in between, they thickened up the layup in a high stress area at the base of the windshield by mooshing the middle fiberglass layer into a corrugated pattern. Thing is, resin rich FRP layups like this are extremely brittle. Which might explain the cracks we were seeing at the base of the windshield. The FRP layup here is almost 1/2″ thick. On the leading edge of the hatch, where they didn’t corrugate the middle layer, the FRP layup is only about 5/32″ thick.

To make up the depth in the FRP layup, we decided to start with another layer of 1/4″ marine plywood.

Since the salon hatch hole measured 5’x10′, I had to scarf three sheets together to fill the space. The upper layer of plywood is oriented longitudinally, whereas the lower layer was transverse. This cross-oriented, two-layer 1/4″ plywood underlayment is reportedly the same layup Weaver Boatworks uses on their multi-million dollar sportfishermen decks.

Vacuum bagging would have been the best approach, but the hillbilly method of laminating works too.

After wetting out both layers of plywood with US Composites 635 epoxy, I coated them with a bonding agent of 635 epoxy and wood flour (wood dust and cabosil). After laying the top panel in place and squeezing out as much air as possible, I started carrying heavy things up the stairs and put them on the salon top. The whole time I’m thinking “I am getting too old for this $4!t”. 😉
The idea was to not have any nail or screw heads on the top layer, since they have a tendency to “print through” the fiberglass and top coat.

On the inside of the boat, I felt I could strengthen the salon top with additional longitudinal pieces.

The original Chris Craft design only had longitudinal pieces around the hatch opening. Weaver Boatworks uses a similar frame structure for the boats (though in laminated plywood rather than solid mahogany), but with longitudinal pieces running down the entire length of the structure.

I added two strakes of 3/4″ plywood longitudinal stiffeners to the salon roof.

The panels are each cut to fit very tightly between the frames, then are edge sealed with US Composites epoxy and glued in place with wood flour-thickened epoxy. I’ll put additional longitudinal stiffeners in all the way from the aft salon bulkhead to the forward-most roof frame before I take down the supports I’ve been using to hold the roof level.

Final bonding of the longitudinal stringers.

After putting a nice fillet on the wood flour-thickened epoxy glue, I used 9oz boat cloth to make the longitudinal stringers a permanent part of the roof structure.

With the path forward worked out for strengthening the salon roof substructure and framing, the next topic in our 1969 Chris Craft Roamer 46 Refit: Stripping the Cabin Top.

1969 Chris Craft Roamer 46 Refit: Salon Hatch Hole Problem Formulation

All of the big Chris Craft cruisers I’ve seen with the headline out had built-in hatch framing in the salon roof. Chris Craft built them into the boats to make repowering that much easier. Our Roamer was repowered with Super SeaMaster twin turbo engines back in 1973, so the hatch had already been cut out once. By the time we had acquired the boat in 2007 the hatch had begun to collapse, which allowed rain from the salon roof to fall inside the boat, eventually filling the engine room. After dejunking the boat, I removed the hatch so I could get the old engines and other big stuff out and put new stuff in.

While the original Chris Craft hatches are well conceived and executed, the reinstallation of the Roamer’s hatch in 1973 was not; hence the collapse.

This is the basic framework for Chris Craft salon hatches.

The mahogany salon roof frames are 1 3/8″ thick and of varying height. They follow the crown of the salon roof and support the 1/4 plywood that underlays the FRP and gelcoat salon top.

The hatch itself is a “box within a box” design, with 1/4 solid mahogany spacers between the two box sections and 3/8″ bronze bolts and washers spaced every 12″ to hold it all together. The open hatch hole on the 1969 Roamer 46 measures 5’x10′.

To remove the hatch, you simply remove the headliner and drill a small hole at each corner of the box. Then strike a line on the top side between the four holes and cut with a saw set to a shallow depth so as not to cut through the bolts. Then, support the hatch from below, unbolt it and out it comes!

Here’s what the frames look like installed in as-found condition

The outline of the hatch in 2007 was a tell-tale that the seam had broken

Upon closer inspection, I found that the seam was only covered with one layer of 3″ fiberglass tape, not much resin and the rest was fairing compound that had long since cracked apart.

All of that was topped with various forms of goo: both rubber and silicone, neither of which kept the rain out for long.

Give me a long enough lever and a place to stand, and I can…take out a salon roof hatch all by myself!

The hatch came out in January 2008. Little did I know it would remain out until 2013.

By 2009 I determined that the hatch skin was shot. Water intrusion through the broken seam around the hatch had rotted out the 1/4″ plywood between the frames and the FRP skin.

This longitudinal outside hatch frame wasn’t horrible, but the plywood was rotten.

Port side aft, the plywood was the worst.

The rot caused the plywood to spread apart, pushing the fiberglass skin up and cracking it at the drilled out hole in the corner.

The plywood rot was really bad on the port side in the middle of the hatch.

The Cause of the hatch collapse: relief notches.

Nobody’s come up with a good explanation for why they cut notches out of the frames when the boat was repowered in 1973. This is definitely not something Chris Craft did originally. This longitudinal frame is actually the best of them all because it only has two small hairline cracks leading away from the tip of the notch.

Three of the four longitudinal hatch frames.

The fourth one was broken entirely at the notch that somebody cut out back in 1973. I’ve already recycled it into cleats (1″x1″ mahogany strips). The bottom one in this picture was almost (but not quite) completely cracked into two pieces.

So, what I started with was rotten plywood, broken frames and a cracked and deformed fiberglass cabin top skin. To fix the hatch and surrounding salon top structure would require stripping out all of the rotten old plywood and bonding in new. Then we’d have to cut new frames to replace the broken ones. Finally, we’d have to reassemble the whole structure that Chris Craft originally created upside-down in a mold from the gelcoat up, but I’d have to do it from the inside of the boat looking up and from the outside looking down!

Next up in our 1969 Chris Craft Roamer 46 Refit: Rebuilding the Salon Roof Hatch.

1969 Chris Craft Roamer 46 Refit: Engines! (right proper ones, this time)

With the paperwork SNAFU finally resolved and the Roamer documented in my name, the missus gave me permission to blast full steam ahead on the refit. One thing that had been troubling me since we moved the boat in 2009 from Colton’s Point to Deale, Maryland was my experience on the Chesapeake at 9~10kts. Unlike the 1967 Constellation 52 I owned at the time, which was a rock at hull speed (relatively speaking), this Roamer 46 was really uncomfortable. Granted, the Chesapeake can be a nasty body of water, and it certainly was that day. The Roamer was also extremely light, which would contribute to it bobbing around like a cork. But the sense I got, especially after talking with other Roamer 46 owners, was that these boats get their stability from speed. And speed was something I wasn’t going  to get out of 120hp Lehmans.

In fact, one Roamer 46 owner up in the Great Lakes contacted me to say that he had Lehman 120s in his! He indicated that, when fully loaded, WOT was 8kts and 1800rpm cruise was closer to 6kts! It was pretty clear that the world cruising sailboater’s suggestion in 2008 to repower with Lehmans was miles off. In retrospect, I should have known better than to trust a ragboater’s suggestion when repowering a classic motoryacht with a fast, planing hull. It all worked out in the end, though. 😉

Fortunately, the economics of repowering were increasingly in my favor. There was at least one silver lining to the economy crashing in 2008: the market for marine engines had crashed just like pretty much everything else. I had been watching all of the usual classified ad outlets for years: Boats & Harbors, boatdiesel.com, boat trader, engine trader etc, and got used to seeing the same engines advertised over long periods of time. After considering CAT, Nanni, John Deere, Detroit Diesel and Cummins, I slowly narrowed down the field to Nanni 320hp or Cummins B or C Series. When a set of Nanni 320s showed up on boatdiesel, I immediately contacted the broker. After a few emails back and forth, he discouraged me from the Nannis and said that what I really needed in the Roamer was a set of Cummins 450 Diamonds…and he just happened to have a used pair with only 400 hours on them.

Throughout 2011, while I was still working on resolving the paperwork SNAFU, the broker continued to correspond with me. Because of the cost of the engines, I also continued surfing the classifieds. In early 2012 I sold my 1967 Chris Craft Connie 52, so I had the resources to buy the Cummins engines. When I got the USCG documentation on the Roamer in May 2012, I presented the broker with my best offer for the pair of low-hour Cummins 6CTAs. I also explained the alternatives that were available, which justified my offer. I was certain the seller would decline or counter-offer but — SURPRISE!!! — Ken, the planet’s best marine engine broker, closed the deal!

The Cummins 450 Diamonds, as purchased

The engines were just outside of Manhattan. I flew up, we test ran them, I bought them and flew back to the Mid-Atlantic.

Within a month, the Cummins 6CTAs were in the boatyard in Deale, Maryland

I shrinkwrapped them so I could prepare for the engine swap. I also bought the refrigerator, washer, dryer and jet bath, since it’s best to move all the heavy and big stuff in one go.

August 2012: Cummins 450 Diamonds in our 1969 Chris Craft Roamer 46

I wasn’t able to take pix on crane day while the Lehmans were coming out and heavy stuff was going in. But this “after” pic captures the view in the salon at the end of the day.

1969 Chris Craft Roamer 46 Engine Room with Cummins 450 Diamonds

The engines are sitting on wood blocks in the engine room. We’ll have to cut off the original 427 gas engine mounts (the rectangular boxes welded to the engine stringers) to make room for the big Cummins engines. Chesapeake Marine Engineering* will be doing the engine fitting and installation. The exhaust, shafts and all plumbing will all have to be replaced.

*July 2013 update: I fired Chesapeake Marine Engineering for failure to get the job done in a timely fashion (one year late!) and because the guy’s welds were completely unacceptable. Fortunately, the welds he did were not in critical areas. I was able to get another welder to redo CME’s shabby work.

While it was nice to finally have right proper engines in the Roamer’s engine room, I did feel a bit foolish for having bought and rebuilt the Lehmans. It seemed like a waste of money…until I compared the price I paid for the Cummins engines in the summer of 2012 to what they were advertised for back in 2008. The yacht market might have been cooling off in ’08, but sellers didn’t “get it” until 2010~11 and prices remained artificially high during that time. I actually spent less on the Lehman/Cummins double repower (my labor is free, of course) than if I had bought the Cummins in 2008!

2013 follow-up: The marine repair shop I bought the Cummins 450 Diamonds from was just outside of Manhattan on the south shore of Long Island. When Superstorm Sandy came to Rockaway Beach in November 2012, the shop was inundated and everything inside was destroyed.

I think the Goddess of the Seas loves old Chris Crafts and protects their devotees. 😉  Unfortunate decisions of mine, uncooperative previous owners, global economic woes and a climatological event of historical proportions all contributed to these Cummins 450s sitting safe and sound in the Roamer’s engine room in 2013.

Next up in our 1969 Chris Craft Roamer 46 Refit: Tent Model IX.

1969 Chris Craft Roamer 46 Refit: Paperwork SNAFU Resolved! Refit Resumes in 2012!

By 2012, it was pretty clear that there was no way for me to get the certificate of satisfaction of lien the U.S. Coast Guard required before they would transfer the documentation into my name. Documented vessel regulations and maritime law didn’t seem to follow the same rules as, say, state motor vehicle regs. Then again, the paperwork SNAFU for my Roamer 46 wasn’t analogous to lost title or mechanic’s lien scenarios. By 2012, with four years and a whole lot of effort into the refit project, I was getting closer to just giving up.

But I wasn’t quite there yet. In March 2012, I gave it one last shot.

In 2011, the previous owner/bum on the beach in Puerto Rico and his estranged wife had signed a bill of sale releasing interest in the boat. Actually, they screwed up four previous bills of sale by adding goofy things to the USCG form. But the one from December 2011 was the real deal, and the USCG accepted it. The only remaining problem was the certificate of mortgage in the USCG file for the boat that needed a certificate of satisfaction of lien from the bank to resolve…but the bank no longer existed. In that final 2011 bill of sale though, they both promised that the Roamer had a clear title in exchange for their acceptance of my dollar (yes…US$1…the purchase price of the vessel…in cash).

So, in March 2012 I sent certified letters to both of them, reiterating their obligation to provide clear title. I told them I’d sue for the full amount of my investment in the boat if they didn’t clear up the lien satisfaction problem with the USCG. That lit the estranged wife up like a Roman candle! The bum on the beach in PR didn’t seem to care, but both he and his wife still owned a house on the beach in Chesapeake Beach, Maryland, and I promised that I’d own a fair chunk of it if they didn’t get me my damned paperwork.

At the same time, I notified the USCG of the trouble I was having. I’d been in contact with them every 3~6 months, letting them know that I was still working on getting the paperwork. Each time the Coasties told me the file was still open. But when I called in March 2012, the nice lady said I should document everything and submit a letter to the CG asking for a case review. Apparently, there is a process by which the USCG could exempt a paperwork requirement if the new owner documented due diligence and had evidence of a situation that was impossible to resolve. Why they didn’t tell me that two years before, I’ll never understand. Maybe they want to see the due diligence part before they share that little secret. In any case, it was good to know there was an alternative route if the certified letter didn’t work out.

But all the sudden, everything worked out fine! I have no idea how the estranged wife did it, but within one month of me sending the certified letter she found the bank that had the records for the bank that carried their boat mortgage three decades before. The USCG got their certificate of satisfaction of lien, and by May 2012 I got a nice envelope from the Coasties with a Certificate of Documentation inside.

The Roamer was mine! All mine!

OK, so in May 2012 the Roamer wasn’t babe of the ball.

But underneath a very tired Tent Model VIII lay a fully sandblasted and barrier-coated Chris Craft aluminum hull that had only seen service in fresh water for 15 years. Heavily built using ALCOA’s finest 5086 1/4″ plate and Kaiser Aluminum’s 6061 extrusions, she was a bantam-weight battle tank!

True, she was a bit dusty and there were a few lichens and moss growing on the underside of the lower rub rail where the rain ran off the tent. But aside from those trivial issues she was coated with some of the finest modern epoxy materials on the planet and faired true by skilled craftsmen! The hull was primed in Awlgrip 545 and ready for final sanding before top coating! The rudders, tankage etc were new! And the plans for the interior were all but done!

While she may have been a diamond buried in a lump of coal back in 2007 when we found her, by 2012 she was a rough cut diamond ready for final polishing!

Next up in our 1969 Chris Craft Roamer 46 Refit: Engines! (right proper ones, this time)

1969 Chris Craft Roamer 46 Refit: A Celebration (and condemnation) of Tents!

With the refit on hold for two years while I tried to secure the documentation, I thought I’d go through a review of the various tents we’ve used in the course of this project. We tried everything from a blue tarp to your basic winter land storage shrinkwrap tent and even free-standing, gargantuan structures the likes of which would awe (or maybe just terrify) Cirque du Soleil!

It’s worth noting that almost all of the tent ratings are more of a reflection on my poor planning and/or execution than on the tents themselves. 😉

Tent Model I (circa January 4, 2008). Your basic cheap blue tarp.

Model I lasted roughly five minutes (grommets failed when lashing it down for the first time). This “tent” rates about half of a star, and that was being generous. Almost a total waste of time and, at $35, not really cheap, either.

Tent Model II (circa January 6, 2008) Your basic boatyard in winter-time white mushroom

Very good as a basic structure to keep out wind, water, and animal life. Fine for inside work, but absolutely precludes hull work. Similarly, deck work is seriously hampered by the confined overhead spaces along the deck–you just can’t stand up in these things unless you’re centerline.

Still, all things considered, including storm worthiness, this tent was a solid three-star performer.

Another view of 2008’s Model II

By April 2008, Model II was ready to retire

With even a hint of east coast spring, it gets hot in these things!

Tent Model III was a welding tarp, with scraps from Model II tied down to cover the cabin top

Model III kept the wind out and sparks in when we were welding up the aft deck in summer of ’08, but it really kind of sucked at keeping rain out of the salon. Not that it mattered, since the entire interior was out while sandblasting happened.

Tent Model III scores a solid 1.5 stars.

Tent Model IV was doomed from the start

The winter of 2008~09 was when we had the big push to get the exterior hull faired and primed. The initial idea was to cover the whole boat with shrinkwrap, but leave it loose and long at the bottom so we could roll it up to work on it and secure it at the end of each day. Yeah…right. Mother Nature and the Goddess of the Seas had other plans.

Every single weekend of that nasty winter of ’08 began with half of each day (both Saturday and Sunday!) spent trying to fix the tent. From November to the end of December, nothing was getting done and the shrinkwrap was taking a beating.

This was a one-star tent, and that was being generous.

Tent Model V, on the other hand, was a beast

By late December 2008, I’d had enough with Model IV and had to re-think my approach. Basically, we left the scrappy remains of Model IV from the deck up, and I built a 2×4 frame around and over the top of the whole boat. We ran a tensioned line around the whole frame at the Roamer’s deck level and welded and taped the upper white part to it. We shrank the upper white part so it was a reasonably well tensioned shrinkwrap tent, but it was completely open at the deck level. One little breeze and things would have gotten exciting… Then we welded and taped the lower section of clear shrinkwrap to make up the rest of the structure all the way to the ground.

Model V was ungodly sore on the eyes but functional as all get out. And tough, too, lasting from December 2008 to July 2009.

All of those shots of the Roamer being faired and primed were taken from inside Model V.

Not the prettiest tent, but Model V did have a certain…presence

Aside from the aesthetic concerns though, Model V also had a horrible design flaw: we gave another shot at trying to have the bottom of the tent loose so it could be rolled up as necessary. While at the bow I used 1×2 battens attached vertically to the uprights to keep the plastic in place, on the sides we only secured the bottom edge using concrete blocks (and anything else heavy that could hold it down).

 

The thing is, Tent Model V was HUGE and so was the “sail area

When the wind kicked up, it tossed that whole row of concrete and 12x12x12 wooden blocks along the bottom edge like they were made of styrofoam. Then the wind got up inside the tent and…holy smokes… I still spent a lot of time on tent maintenance and repairs, but Model V was so good in most respects it easily deserves four stars.

By order of the marina management, Tent Model V was decommissioned in July 2009

But I kept the white plastic to use as a temporary shelter (AKA Tent Model VI). I also kept the 2×4 structures and scaffolding for reuse later.

Tent Model VI was an obvious rip-off of Model III

But the now-finished aft deck enclosure structure made for a slightly more aesthetically pleasing result than Model III. The method of securing it was vastly improved, too, with the plastic held in place around the base of the cabin top with a highly tensioned cord. I also had 2x4s arranged across the still-open salon hatch hole so rain ran off..sort of. The 2x4s are absolutely critical for keeping the world’s largest water balloon from forming inside the salon. I’m talking…like…75 to 100 gallons in the shrinkwrap sagging precariously through the salon hole.

Don’t ask how I know about that.

Tent Model VII rated a solid three stars

OK, so the boat shed at Colton’s Point Marina doesn’t technically count as a tent, especially since Tent Model VI was still on duty. And it didn’t have anywhere near the panache of Model V. And we couldn’t do any work in Model VII that generated construction noise or dust on account of the neighbors. But, for a brief moment in time, “Tent” Model VII made the Roamer fit in with the other, normal boats. It was a nice reprieve after two decades on Purgatory Row.

 

You wouldn’t know it from this picture, but Tent Model VIII was basically identical to Model II: a white boatyard mushroom

But its first year in service (winter of 2009-20010) was the year of Snowmageddon in the Mid-Atlantic. Am I the only one who just shuddered at the memory?

Under a 36″ cumulative load of snow, Tent Model VIII collapsed onto the cabin top, resulting in a broken wooden center support for the port side salon window opening. The salon hatch was still out and, in anticipation of forthcoming repairs back in early 2009, there was very little structure remaining in the cabin top. I wasn’t making regular visits to the boatyard because the process of documenting the boat in my name simply wasn’t progressing, but I went out after the big storm and taped up the tent. It was disheartening to see the cabin top structure further damaged, but without clear ownership I wasn’t going to spend any additional time fixing it. My primary concern was to protect the rebuilt Lehman engines, Fischer Panda genset and other things that had value above scrap. This picture was of Model VIII after two and a half years of hard service.
Model VIII gets four stars because even though it was really just a Model II in a different marina, it took Snowmageddon on the chin and kept protecting the Roamer for another 30 months with very little support from yours truly.

Tent Model IX, the current 2013 iteration, is by far the best, gnarliest tent of the bunch. I’m talkin’ so superior in every possible way to any tent ever made…well…Cirque du Soleil is no doubt envious. But that post will have to wait just a bit. 😉

Next up in our 1969 Chris Craft Roamer 46 Refit: Interior Concept Drawings

1969 Chris Craft Roamer 46 Refit: Paperwork SNAFU, Splashed, Moved and Tented!

While the refit had been progressing from December 2007 to July 2009, I had been trying to get the vessel documented in my name. Problems first arose when the U.S. Coast Guard notified me that the previous owner’s signature on the bill of sale was inadequate because both he and his wife were on the documentation. This was a problem because the guy was apparently living on a beach in Puerto Rico and his estranged wife was somewhere in New England! If they had divorced like normal people, she would have been more easily discoverable.

While I became a private detective to try and find the estranged wife, the USCG notified me of a second problem: the previous owners had filed a certificate of mortgage on the Roamer way back in the 1980s, but they never filed the paperwork to certify that the loan had been paid in full. The guy was still in PR, so it was extremely difficult to contact him. The wife, when I finally found her in 2011, was upset at the thought of having to interact with her husband and deal with the Roamer again after so much time. Both swore the loan was paid off, but they had no paperwork and the U.S. Coast Guard doesn’t take pinky finger promises. Worse, still, was that the bank on the USCG certificate had long-since been bought, sold, merged, acquired and sold again.

How, exactly, does one get a copy of a certificate of lien satisfaction from a bank that hasn’t existed in decades?

After all of the effort invested in the boat, it looked like a paperwork snafu was going to stall the project. I’d been slaving away for 20 months on the assumption that the paperwork would come through in a month…and then another month…and then another. Son of a ….

As if it wasn’t enough that there was no end in sight on the paperwork problem, new owners at Colton’s Point Marina were uppity about every boat on Purgatory Row (even the big one that was getting prettier by the month). Seeing the writing on the wall, I made the decision to splash the Roamer and bring her around to a marina in Deale, Maryland to finish out the refit…assuming I could square away the paperwork.

In September 2009, the Roamer’s bottom was painted and the rudders and shafts were in, so we splashed ‘er

First time in two decades that she’d floated.

Because there’s no interior, furniture, fuel, water or windows on the boat, she’s riding a bit high in the water

So high, in fact, that the aft corners of the transom were inches above the surface of the water!

The Roamer left Colton’s Point Marina on October 14, 2009

Destination: Deale, Maryland…just down the Potomac River, around the bay and up north a few hours.

Leaving the last channel marker on the creek leaving Coltons

Though conditions were quite calm, things got choppy out on the Chesapeake. Message from the near future: Probably should have strapped that stuff down on the cabin top a bit better…

Into the Chesapeake!

Just shy of 10kts and she’s rapped out and on plane!

Varoom! Water skiing, anyone?

Ah, the calm serenity of the Chesapeake when the tide and wind changes

WHOA!! There went two of those sheets of 1/4″ marine douglas fir that were on the cabin top!

Within a few hours, the Roamer was safely moored in Deale, Maryland

Along the way, pretty much everything but the battery that had been on the cabin top when we left Coltons found its way into the Chesapeake!

Note to self: Remember grandpa saying that no matter how much you want to stay on schedule, always make sure things are properly secured before leaving port?
Grandpa was a very smart man.

Back the Roamer goes, onto dry land

Given the problems with the documentation, I was really hoping this wouldn’t be the last time the Roamer floated.

October 17, 2009

The Roamer sits out in the farthest reaches of a boatyard in Deale, Maryland. Land-bound again and paperless.

Though unsure of whether or not I would eventually get the title squared away, I didn’t want to just give up and sell her off as scrap. With winter coming on, I tented her up and focused on securing the documentation. Little did I know the effort would take almost two more years…

Next up in our 1969 Chris Craft Roamer 46 Refit: A Celebration (and condemnation) of Tents!

1969 Chris Craft Roamer 46 Refit: Priming the Hull, and Painting the Bottom

May 10, 2009. We’d been wailing away on the Roamer refit for 18 months, and it was finally time to seal up the hull in primer and then paint the bottom.

The stem and forward hull in 2007

Same spot in January 2009

Primed and ready for final sanding and top coat in May 2009

The chine in 2007

The chine in February 2009

The chine (opposite side) in May 2009.

A long view down the side in 2007

A long view down the side in 2009

 

Struts in 2007

Struts in May 2009

Full frontal ghost ship in 2007

Full frontal ghost ship in 2007

Full frontal much loved Roamer circa July 2009

You really can’t get much more “before” than this

This is kind of a partial “after.”

The bottom was painted in Pettit Vivid for aluminum hulls, but the topsides were still in Awlgrip 545 primer. The aluminum aft deck was still not primed, the decks were sandblasted but not faired or primed. And the cabin top still had the 5′ by 10″ hole cut in it from the engine install.

But the project was was getting there!

Next up in our 1969 Chris Craft Roamer 46 Refit: Paperwork SNAFU, Splashed, Moved and Tented!

1969 Chris Craft Roamer 46 Refit: Fairing the Topsides

By the end of February 2009, we were fairing the hull sides. My initial approach was to get it basically back to the same degree of smoothness as it would have had coming off the Chris Craft line back in ’69. Later, after getting a good look at the waviness of another aluminum Roamer with shiny paint compared to the fiberglass Hatteras next to it, plans changed and I decided a nice, smooth hull was best. Around the same time, I was lucky enough to meet the boss of the fairing crew at Weaver Boatworks, who have extensive experience fairing brand new, multi-million dollar sportfish yachts.

The view from the port transom looking forward

The surface we were working with was a combination of sandblasted original fairing compound (that was well adhered) and blasted and treated aluminum. The blue stuff is vinylester fairing compound.

Lots more vinylester fairing compound

Skimcoating the hull

Makin’ ‘er blue from the chine up

It was around this time that we realized how wavy this aluminum hull would be once painted and shiny if we used only minimal fairing compound. Through a chance meeting with the fairing crew boss at Weaver Boatworks, we decided to make the Roamer as fair as Weaver’s multi-million dollar sportfish yachts.

The lower hull side gets a real fairing coat

This fairing compound consists of US Composites 635 epoxy mixed with their SM Fairing Compound powder. The fairing crew boss is getting the scaffolding ready for the guys in April 2009.

Enter the Boatamalans

Boatamalan: Noun. joking reference to the Central American origin of the fairing crew (boat + Guatamalan).

The fairing crew from Weaver showed up every Saturday and Sunday for six weekends straight. The guys are some of the hardest working, most skilled craftsmen I’ve ever run into. Not a single prima donna in the bunch.

One monolithic layer of fairing compound.

Next came the hard part: longboarding.

Go Boatamalan! Go!

You can see some of the blue vinylester where they’ve sanded down to a high spot.

At this point, the hull was faired straight except for a few touch up spots.

By May 10, 2009, the fairing work to the hull was done. Next up: Priming the hull and bottom paint.

1969 Chris Craft Roamer 46 Refit: Rudders

Way back in the 1980s, the previous owner had the Roamer towed from Washington DC to Colton’s Point Marina in southern Maryland. One of the guys who did the tow said it was particularly difficult because the rudders were locked in position. The Roamer wanted to turn to the left all the way down south. When we got the boat, I found the steering gear broken and the rudders absolutely unwilling to move. We ended up cutting them out and having new ones made.

The key phrase here is “dissimilar metals”

The original plain steel rudders were frozen in time…circa 1985, I do believe.

The rudder view from the inside

Here we have the aluminum Schedule 40 pipe for a rudder shaft log, through which runs the rudder shaft itself. Threaded onto the top of the aluminum pipe is a standard bronze packing gland nut. Three different metals (more, actually, because they’re all alloys) in a water environment. Add to that the fact that the boat didn’t move for years before it was finally hauled and you have a seriously locked up rudder shaft. I was unable to remove the gland nut even with a 4′ pipe wrench. Penetrating oil didn’t help. Heat did nothing.

A 12 ton ram chained to the rudder achieved…nothing but an interesting photo opportunity

Again, heat did nothing. These rudders were simply not coming out.

Enter the sawzall. And out came the rudders! 😉

Note that there is a grease nipple on the log. From the look of it, the logs hadn’t gotten a maintenance shot of grease since it left the factory in 1969.

With the rudders out, I sent one off to a fabrication shop for replication

What came back from the fabricator was a nice set of brand new stainless rudders and hydraulic steering gear

The tie rod is actually straight though it looks curved in the pic

The view from the inside

Rather than threading a bronze gland onto the aluminum, we’re using a shaft log hose and spud approach that will isolate the aluminum from the bronze. The Devoe epoxy coating will also help isolate the aluminum from the carbon in the hose. Most important, though, is that we will actually use the boat, so the rudders will be less likely to lock up solid.

The new rudders from the outside

We took a different approach with these than Chris Craft did. The rudders don’t come into direct contact with the aluminum log. Instead, there is a delrin sleeve pressed into the log and the stainless rudder shaft turns inside that. For all intents and purposes, the stainless is isolated from the aluminum, at least in the wet part of the system

In retrospect, plain steel rudders in an aluminum log with a log hose and spud might be a better approach than the delrin sleeve. With a shot of grease into the logs, there’s no reason why the original Chris Craft approach wouldn’t work well. In fact, plain steel is less aggressive against aluminum in a wet environment than stainless steel. Check your galvanic series if you don’t believe me. 😉

My concern with the delrin sleeve is that if aluminum oxide forms between the log and the sleeve, it will compress the sleeve and squeeze the shaft–perhaps causing it to bind. While the same thing could happen in the original configuration, if you drive the boat and turn the rudders, the Al2O3 ought to turn to paste and be flushed out when you go through the water. If the Al2O3 is stuck behind the delrin, which doesn’t rotate, then I don’t see how it will be flushed out.

In any case, it’s too late now to change things based on theory alone. Maybe the delrin will work flawlessly. Time will tell.

Next up for our 1969 Chris Craft Roamer Refit: Fairing the Topsides.

1969 Chris Craft Roamer Refit: The Exterior Hull

Over the 2008-09 winter, we tented the Roamer and began refinishing the exterior hull. The sandblasting left a surface that was ready for barrier coat, so we applied Alumiprep and Alodine and started rolling on the Devoe 235 epoxy. Devoe is a major supplier to the U.S. Navy, and their epoxy coatings are widely used in harsh industrial applications (e.g. large tanks etc). With the barrier coating done, we did some limited fairing work. The initial plan was to make the boat only as fair as Chris Craft did, which is to say not especially fair when compared to the fiberglass Commanders, for example. Later, when I discovered a fairing crew out of Deale, MD, we changed plans and had the boat fully faired to a very smooth surface.

This is what the bow looked like shortly after we took possession in late 2007

And this is what the bow looked like in January 2009

That underwater fairing compound is spendy…$38/liter!

The bottom just abaft of the stem in January 2008

Same spot in January 2009

Some unpleasantness along the chine in 2008

And a bit more…

Same area in January 2009 after a good sandblasting and barrier coating

The transom in 2008 still had those really neat underwater exhaust deflectors

The thing about those exhaust deflectors is that they were made of a thick rubber-like compound that was black (i.e. containing carbon) that were bolted to the aluminum hull with bronze bolts (containing copper)? I’m sure they made the boat very quiet, but just look at the aluminum oxide nearby! Repeat after me: dissimilar metals are bad, and aluminum almost always loses!

Here’s what I found when I took the deflectors off

Under the deflectors, I found aluminum oxide under the fairing compound for several feet around each of the exhaust pipes. Fortunately, the sandblasting got rid of all that.

Aluminum oxide blasted away, then the transom got faired and barrier coated

I welded in brand new 3.5″ exhaust tubes in Schedule 40 pipe. Two 20′ sticks cut down to 15′ all the way from the transom to the engine room. That was all the Lehman engines would need, after all…

This was the long view of the bottom in January 2008

One good thing about this boat was that even though she’s 40 years old, she’d only been in service for about 15 before being hauled and blocked on land. There just wasn’t any aluminum wasting to speak of.

Same bottom in January 2009

It looked even better after sandblasting, barrier coating, and a bit of fairing compound to smooth over weld joints and other minor surface imperfections.

Next up (though somewhat out of sequence) 1969 Chris Craft Roamer Refit: Rudders