Cosmos Mariner is a 45 steel Chris Craft Roamer that came to us to have the bottom sandblasted and epoxy coated and a new electrical system installed. We had found evidence of severe electrolysis and discovered there had been current leaking from both the A.C. and D.C. systems. As we were sandblasting we found spots of metal so thin that we went through the hull. After checking the entire bottom with an ultrasound, we determined that major sections of bottom plate would have to be replaced, This is the port side transom corner.
This is the starboard transom corner. The numbers on the transom surface indicate the metal thickness. The metal plate was originally 3/16″ thick or .1875″ thick.
Severe rust damage has been occurring in this section. The gas fuel tanks were located above this area inside, and prevented routine inspection and maintenance.
Most of the damage to the hull was in aft sections of the boat where there was no access to maintain the steel from the inside. These areas were under the aft stateroom and the aft head. The cabinsole was not removable so this metal had been left untouched for over 40 years. We pulled 4 – 5 gallon pails of rust scale out of this section.
This shot is of new metal in the engine compartment. The batteries had leaked on both sides of the boat over the years and these area need replacement as well.
This is new metal that was replaced under the head area.
Here we are checking the new longitudinal framing before installing the new plate.
Section of plate tacked in place ready for final welding
These following photos show the replacement of the severely rusted out exhaust outlets and their replacement.
After the metal had been replaced we needed to deal with the two engines that needed replacement. Unfortunately their was no easy way to get them out and the new engines in with out stripping them down to blocks which would add considerable unneeded expense to the engine replacement. We decided we would be ahead of the game bycutting a main hatch into the cabintop and pull the engines out from the top.
The new engines will go in after a major rewiring effort is completed. We will be upgrading both the A.C. and D.C. systems with new panels and bringing the wiring up to current ABYC standards.
Covered for the winter - only5 months till spring !
Project: Cosmos Mariner
Cosmos Mariner is a 45 steel Chris Craft Roamer that came to us to have the bottom sandblasted and epoxy coated and a new electrical system installed. We had found evidence of severe electrolysis and discovered there had been current leaking from both the A.C. and D.C. systems. As we were sandblasting we found spots of metal so thin that we went through the hull. After checking the entire bottom with an ultrasound, we determined that major sections of bottom plate would have to be replaced, This is the port side transom corner.
Most of the damage to the hull was in aft sections of the boat where there was no access to maintain the steel from the inside. These areas were under the aft stateroom and the aft head. The cabinsole was not removable so this metal had been left untouched for over 40 years. We pulled 4 – 5 gallon pails of rust scale out of this section.
These following photos show the replacement of the severely rusted out exhaust outlets and their replacement.
After the metal had been replaced we needed to deal with the two engines that needed replacement. Unfortunately their was no easy way to get them out and the new engines in with out stripping them down to blocks which would add considerable unneeded expense to the engine replacement. We decided we would be ahead of the game bycutting a main hatch into the cabintop and pull the engines out from the top.
The new engines will go in after a major rewiring effort is completed. We will be upgrading both the A.C. and D.C. systems with new panels and bringing the wiring up to current ABYC standards.