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1994 Protour 190 Restoration

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  • RDahler
    replied
    1994 Protour 190 Restoration

    Next I removed the LT1 engine and Power Slot transmission from the hull.
    Attached Files

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  • RDahler
    replied
    Hi Bret
    1994 Mastercraft Sponsored Pro Skier Jeff Rodgers this was his boat.

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  • RDahler
    replied
    I do agree with your thinking on the screen on the end of the pick up and almost removed it during the rebuild. The rubber hose that is used to connect it was hard to source it had to be rated for fuel submerge. It just fell apart when I touched it I guess 26 years is to long to be submerged in fuel.
    On this fuel cell the pickup and fuel level probe extend down in to a removable compartment that isolates them from the main fuel supply by a small 1/4 hole used to keep it filled. This is used to keep the fuel pickup submerged and the engine running in hard turns.
    All the trash that had collected over years had collected out side of the compartment and the screen was clean. The marine anti siphon valve attached at the top of the pick up and is located before the external in line filter.
    The reason I kept the screen I had a bad experience with trash collecting in the anti siphon valve on my 88 190 the engine would randomly quit and after sitting for about 10 minutes it would restart and run like nothing had happened. The trash would slowly work it's way back down the pickup tube as we sat. Then the process would repeat some times every other trip to the lake some times two or three times wile at the lake a real PITA.
    Last edited by RDahler; 05-28-2021, 01:52 PM.

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  • bret
    replied
    Which Pro Skier had the boat and set a world record at the time, sorry my days offshore have clouded my memory.

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  • waterlogged882
    replied
    Originally posted by RDahler View Post
    When I disassembled My fuel cell the 1/2 inch pickup tube was connected to a funnel shaped pickup with a fine screen on the bottom of it by a short rubber hose with two clamps. It was positioned 3/8 inch off the bottom of the tank. With this configuration I would suspect the amount of unusable fuel is between one or two gallons at the most.
    Agree.

    For me and at that point, the screen comes out. One less thing to potentially cause a fuel supply issue.

    I figure anything that comes through will stop at the fuel filter.

    .

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  • RDahler
    replied
    When I disassembled My fuel cell the 1/2 inch pickup tube was connected to a funnel shaped pickup with a fine screen on the bottom of it by a short rubber hose with two clamps. It was positioned 3/8 inch off the bottom of the tank. With this configuration I would suspect the amount of unusable fuel is between one or two gallons at the most.
    Last edited by RDahler; 05-28-2021, 12:08 AM.

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  • MIskiboat
    replied
    The fuel tank is mislabeled. At least for our 94. Since the pickup is not on the bottom, there is approx 5 gallons you can’t really use. So that is really “E”.

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  • Miss Rita
    replied
    Good thing they put the "F" and "E" on the tank.


    I also thought the 1/2 full mark is useful

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  • stuartmcnair
    replied
    Originally posted by RDahler View Post
    Next the fuel cell it had a lot of vapor escaping from it. Removed it from the hull and disassembled. The the gaskets that go around the housing had cracks and NLA.
    I made a aluminum template to cut out replacement gaskets and put sealing washers on all the screws.
    I pressurized the tank with a shop vac and sprayed soapy water on it to check for leaks.
    Problem solved.
    The fuel tank has fuel levels marked on it take a look at the photo as a guess I think they were adjusting the fuel load for the number of people in the boat to keep the pulls consistent.
    Good thing they put the "F" and "E" on the tank.

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  • Prostar 190
    replied
    Nice work.

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  • RDahler
    replied
    Next the fuel cell it had a lot of vapor escaping from it. Removed it from the hull and disassembled. The the gaskets that go around the housing had cracks and NLA.
    I made a aluminum template to cut out replacement gaskets and put sealing washers on all the screws.
    I pressurized the tank with a shop vac and sprayed soapy water on it to check for leaks.
    Problem solved.
    The fuel tank has fuel levels marked on it take a look at the photo as a guess I think they were adjusting the fuel load for the number of people in the boat to keep the pulls consistent.
    Attached Files
    Last edited by RDahler; 05-27-2021, 09:51 AM.

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  • SwissCraft1291
    replied
    Originally posted by RDahler View Post
    The Foam seal that runs under the bottom of the windshield all the way around. Trim Lok Boat Dual Seal Molding X-1333 HT 3/4 Great Lakes Skipper PN 1070904 they sell it by the foot I ordered 16 feet you can by it from there sight or from them on EBAY. You will have to remove the complete windshield assembly you can not just slide off the center section. The new seal has two adhesive stripes on it and just sticks on the bottom.

    Great! Thank you for sharing.

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  • RDahler
    replied
    more pictures
    Attached Files

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  • RDahler
    replied
    1994 Protour 190 Restoration

    This seems to be a common problem the Aluminum Honeycomb floor panel behind the engine cover were the hinges attach just gets reamed out over time. This type of floor panel needs a Aluminum Doubler under it to spread the load. Mastercraft at some point fixed this problem by adding a Doubler.
    The four screws that hold the panel in place are also problematic.
    I decided to replace with 1 inch Marine Coosa Board Bluewater 26.
    The original panels Weight 7 pounds. The Cossa Board 16 pounds.
    I fabricated a Doubler out of some 1/4 T6 Aluminum plate and mounting brackets to get the screws off the edge of the panel and threaded all the screw holes to make it easy to remove.
    This should be a permanent fix to this problem.
    Attached Files
    Last edited by RDahler; 05-26-2021, 07:52 PM.

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  • Prostar 190
    replied
    Originally posted by RDahler View Post
    Next I removed the windshield from the boat and carefully the frames from the glass.
    The original black paint was striped from the frames. I had the Aluminum frames Black Anodized and reassembled to the glass.
    Looks great!

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