Well this project is taking just about forever. I didn't post much about it during the tear-down so I guess I'll post in the reverse!
The project started as "I'll just replace the carpet". To get the carpet out the ENTIRE inside of the boat had to come out.
Not awesome. Not at all.
Once it was gutted to the floor I felt the foam through some holes that were drilled in the aluminum floor (there is not ONE SINGLE piece of wood in this boat, 100% aluminum). The foam was soaked. I drilled the rivets on the floor and pulled up all the panels exposing the waterlogged foam.
Removing the foam is the worse. Job. Ever. I'd rather stick a needle in my testicles than do this job again. Dead serious. There's no easy way. It's knuckle bleeding manual labor. The transom was filled with foam. I had to cut access holes into it (non structural panels) to rip the foam out. Those 2 pods in the transom were the most difficult to clean out.
With the foam 100% removed I used a pressure washer to clean off the residual scraps of foam. With the hull clean I identified a few cracked welds that secure the support beams to the hull. I found a local shop to repair the welds.
I ordered foam from FSIfoamkits.com. You can check my review of that company in the Restorations forum. They are FANTASTIC. I poured the foam today. The high spots will be cut flat and all cuts will be sealed with a waterproofing paint (Killz).
Carpet is 16oz Syntec. I'll be using Weldwood original on almost all the carpet. The carpet on the floor of the rod lockers will be secured with 3M Super 90 spray adhesive. I need something with some working time and forgiveness to work the contours of of the hull that make the bottom of the lockers. The carpet also tucks up under the gunnels. I imagine that would be almost impossible with contact cement.
The livewell plumbing is being replaced and upgraded. I'm putting in 2 1000gph fill pumps, 2 1000gph aerators (one with pump-out) and a 1000gph automatic bilge. All hoses are being replaced and I'm using Flow-rite QuikLok fittings.
I had some motor work done. The exhaust tuner came loose on the XR6 so I had a Bob's tuner installed. I also had solid motor mounts installed and sent the heads to JSRE to be shaved.
I'll attach more pics as I get her back together. This game sucks.