Another BFN Rebuild

Probably too busy cruising in the ORANGE CRUSH     

Once again, we're overdue for an update. Time for a little bit of catch up...

To accomodate the wider exhaust manifolds, we had to widen the motorbox 3". The first step was to grind off all the gel on the inside, and then cut it in half:





I took the wood out of the rear of the box that served as a backer for the hinges... it was rotten. I attempted to remove the wood from the top of the box, but it was solid (and dry), so it's staying.

Next, I reconnected the top.







And then the front and back.





Now, Im in the process of strengthening the box, and raising it a bit. This will accomodate any future growth in height (intake manifold, carb spacers, etc).

The front side in progress:



I stole a trick from Roger and glassed around a piece of PVC... this piece will be cut in half and then glassed to the front edge of the box to serve as a small relief around the pylon. Ive seen this notch in Ski Tiques and Nautiques- not sure why the BFN didnt get it. Hopefully improving the clearance around the pylon will prevent the aluminum trim from further scraping it up.

The back edge is already done... once the front is dry, then its on to the sides, and then the corners.






In the meantime, we've been making progress on the engine and interior as well.

Only the removeable front panels still need carpet- the trim is complete, as are the pockets, rear panel and battery box lid.









I decided to try my hand at gelcoating, so after a conversion coat of vinylester, the battery box lid, driver's seat pedestal and rear panel all got several coats of gel brushed on.





The gel was great to work with, though completely different than the epoxy. The opaque gel covered great- I will definitely be using it in the bilge on future projects. The brush marks didnt lay down perfectly, but its good enough for the underside of the lid and rear panel. Ill probably spend some time sanding and smoothing the pedestal.

We ran the wire harness and bilge pump lines, and connected the exhaust hoses. Clearance was tight to the panel and motorbox, so we added some 45 degree SS elbows to help make the bend under the floor.



We finished all the work at the transom- connected the speedo lines, wired the light and fuel sender, connected our gas lines and installed the tank.



Dad also put a lot of work into the cooling system- all new hoses and clamps, new 'stat housing, etc. He also rigged up all of the new control cables and brackets and installed the new battery cables.





In an attempt to "pretty" the boat up as much as possible before last week's CT get together, you'll notice we also installed the pylon, steering wheel, and shift knob... hopefully Joel is pleased!

Last night, we cranked the motor for the first time since 2009 and broke in the cam. Other than a few small hiccups, everything went well. Now we need to break down the valvetrain and reinstall our inner valvesprings. Once thats done, theres little keeping us from doing a water test... so it wont be long now!

can´t wait to see her breaking the 60+ mark!!! jajaja
looking gooood

Absolutely fantastic!! Hopefully you'll give me a ride or even better yet allow me to get behind the helm!

Thanks guys.

Bruce, the box wasnt (and still isnt) much to look at. We stored it out of sight behind Brad's camper!

wakeboardin2k4 wrote: It's probably been mentioned but 26 pages is too much to search through for this question...

Eric,
Sorry if I missed it but what's the question that requires reading 26 pages?

wakeboardin2k4 wrote: What's the plan for a prop? Same one you guys were running or are you going to have to play around with props till you find the right one for the added HP

If you haven't noticed, Tim is defiantly "Mr Prop" so I'm sure he has a plan!!
Tim,
Yes, what is the plan? Original prop to start but then see how it spins at a higher RPM?

wakeboardin2k4 wrote: That was the question lol

GOT IT!!! Yes, you must understand that Tim is extremely detailed and to the point as being as anal as myself!!! 26 pages proves it!

Real nice Tim

Thread Hijack- Eric, I know your the guru at rebuilding these transmissions are you equally well versed at E40D transmissions? Mines slipping after my trip to the CT mini reunion

95000 mile oils not burnt, was low but no apparent leaks. First time it slipped was 4th gear going up a hill on the highway with my trailer and empty barracuda behind it. Maybe 2000lbs. Did 3 fast slips in a row before I let off the throttle for it to catch. Otherwise it's done it mostly in second gear with no trailer on the truck. Has slipped maybe 6 times in the past week.

Speedo has been accurate and no weird ABS light but I'll keep my eyes open for it. No tow mode. Trucks a 95 f350 diesel so before the days of tow mode.

I've had nothing but terrible luck with this truck and I keep pouring money into the stupid thing

I'll find that speed sensor an replace it.

Here's another "clue" about the issue I'm having. Twice the truck has died while driving. Flat out shut off for half a second then kicked back on no problem and once the trans slipped while downshifting into second when I got on the brakes.

the speed sensor is also tied into rear abs also,
TR i was pulling your joint and do remember seeing the trans pics, ive been skimming your thread for 2 years now, just waiting for the big day

The pan doesnt look like aluminum to me... I assume its the original OMC pan.

We made an honest attempt to keep it looking as original as possible... until you pop the engine cover anyways.

I finished raising all 4 sides of the motorbox and pieced in the corners last night. Hopefully Im just a few days away from being able to brush some gel on it. Pictures to come!

Tim this boat looks awesome! I like the aluminum bracket on top of the strut bolts to mount the steering cable. Is that your idea?
Scott