1994 Protour 190 Restoration

[RDahler]

I transported the new Ridged Rub Rail to the house last night it only comes in 20' sections so it took three of them. They came well packaged in a plastic tube to prevent damage in shipping.

[RDahler]

I was afraid of that. Mine is pretty weak in the air where the dog house bolts to it.

I found these guys but have yet to check on pricing and what not.

https://www.portafab.com/alum-on-alum.html

You may want to take look at my post #13 and #14 to see how I fixed my floor boards.

[CantRepeat]

The original floor board was 1 inch aluminum honeycomb very stiff and light about 14 pounds.

I was afraid of that. Mine is pretty weak in the air where the dog house bolts to it.

I found these guys but have yet to check on pricing and what not.

https://www.portafab.com/alum-on-alum.html

[RDahler]

3/4 king starboard? What was the original material?

The original floor board was 1 inch aluminum honeycomb very stiff and light about 7 pounds.

[CantRepeat]

more pictures

3/4 king starboard? What was the original material?

[d2jp]

Great work and thanks for sharing the details. A lot of what you've documented is beneficial to all prostars of that era....and probably before and after that era too.

[waterlogged882]

Thank you Sir. Much appreciated. That is good stuff right there.

.

[RDahler]

Chuck asked me to go over the process of replacing the windshield bottom gasket.
You will need to remove all the screw cover foam. The windshield is held on by 14ea 8-32 x 11/4" screws in the channel and two ea 10-32 X 2" screws located at the rear of the side glass frame the heads are painted black. Do not remove any other screws from the frame. Some things to be aware of the windshield is just sitting on the gasket you take all the screws out it can just fall off the boat.
This is a two man job (do not ask your wife for help this is way above asking her to hold a screw driver for you)
To lift the Windshield one hand under the slip joint were the side frame connects to the center frame the other hand goes under the middle of the side glass on each side.
You will need to lift it up about 6" and walk it straight over the bow and set it on a padded surface.
The tricky part you will need to flip the windshield up side down to remove the old gasket and install the new one. The windshield will not support it self up side down trust me on this one. I ended up removing the four center dowels from the wooden glass holder I made and had to shim the back end for the correct angle see photo.
The new gasket I ordered it from Great Lakes Skipper 16 foot 1070904-5C291 Trim Lok Boat Dual Seal Molding X-1333 HT 3/4 inch the new seal is applied in one continues run all the way across the bottom and centered over the mounting screw holes. Reverse the process set the windshield back on the boat line the holes up and reinsert all the screws washers and nuts.
Do not over tighten the nuts. I worked from the rear of the side glass to the slip joint on each side first then from the slip joint to the center of the front glass and the two long screws last.
First photo glass holder.
Second photo glass holder with dowels removed to prop up inverted windshield assembly.
Third Photo left over section of new gasket and on the left new hardware right old hardware.
The last two photos show the inside and outside of the new gasket.

[RDahler]

What size was the exhaust hose on this?

This boat built was built early in the 94 production run June of 93 and had 3 inch exhaust and that is what I put back on it. Some time during the 94 production run they increased the size to 3.5 inches.
The 3 inch exhaust fits snug under the rear floor section. I do not know how you could get the floor screwed down with the 3.5 exhaust hose under it.

[CantRepeat]

This weekend I dropped the engine back in hooked up the exhaust system and installed the windshield.

What size was the exhaust hose on this?

[MIskiboat]

Too bad we didn’t live closer. If our kitchen table was ever a mess, we could simply come eat dinner off literally any square inch of that clean clean boat.

Awesome work. Thanks for the detail and updates. Love the 91-94’s.

Gonna be a great tug here shortly.

[2RLAKE]

wow that is simply incredible!

[waterlogged882]

.

[RDahler]

This weekend I dropped the engine back in hooked up the exhaust system and installed the windshield.

[Jeffer]

it'll be a shame that so much of this beautiful work will be hidden behind panels, floorboards, and upholstery. Your work is so nice, it should be in a cut-away (not good for floating boats) or behind glass (also probably not good for floating boats). It's MC museum quality.
...in other words, nice work.