Hobie Cat Forums

It is currently Thu Aug 21, 2014 2:07 pm

All times are UTC - 8 hours [ DST ]




Post new topic Reply to topic  [ 72 posts ]  Go to page Previous  1, 2, 3, 4, 5  Next
Author Message
PostPosted: Wed Feb 20, 2013 12:15 pm 
Offline
Site Rank - Captain

Joined: Sun Aug 16, 2009 3:24 pm
Posts: 92
Location: Waverley,Nova Scotia,Canada
VERY IMPRESSIVE!!!

Regards....


Top
 Profile  
 
PostPosted: Wed Feb 20, 2013 2:05 pm 
Offline
Site Rank - Captain

Joined: Mon Nov 26, 2012 9:43 pm
Posts: 88
Location: Rolla, Missouri
Ok. Back at it. Fill welded the other forward bungee hole.

Image

Welded two pieces together for the rear section in front of the seat. This will serve a couple purposes. It will once again make the floor water tight and also cover the rear threaded bungee holes.

Image

Bungee hole sanded.

Image

Rear piece sanded.

Image


Last edited by ckossuth on Fri Feb 22, 2013 12:05 am, edited 1 time in total.

Top
 Profile  
 
PostPosted: Wed Feb 20, 2013 5:13 pm 
Offline
Site Rank - Captain

Joined: Mon Nov 26, 2012 9:43 pm
Posts: 88
Location: Rolla, Missouri
A little more cutting. I had to cut a recess into the bungee wells for the new back piece to go (The bottom of the bungee wells will be removed later). This will allow it to equal the level of the existing floor and create a smooth transition.

Image

I used my heat gun to bend the piece into a 90 degree angle. Clamped it in place and hosed it down with cold water.

Image

The result.

Image

Spent a lot of time getting it just right.

Image

Ready for the back piece.

Image

Nice fit. Ready to be welded.

Image


Last edited by ckossuth on Fri Feb 22, 2013 6:53 am, edited 2 times in total.

Top
 Profile  
 
PostPosted: Wed Feb 20, 2013 6:30 pm 
Offline
Site Rank - Old Salt

Joined: Tue Jul 19, 2005 6:29 pm
Posts: 2028
Location: High Point, NC
Outstanding.


Top
 Profile  
 
PostPosted: Wed Feb 20, 2013 9:26 pm 
Offline
Site Rank - Captain

Joined: Mon Nov 26, 2012 9:43 pm
Posts: 88
Location: Rolla, Missouri
The hard part is almost over. Here's the back piece tacked in.

Image

My "high tech welder".

Image

Welding finished.

Image

Sanded and smoothed. I used the adjustable low heat setting on my heat gun to rewarm the area after sanding. As the material heats up, any imperfections in the sanding glaze over and blend into the rest of the piece. This gives it a near factory finish.

Image

Image

Image

Image

Thanks for all of the kind comments and encouragement. After I work around the scupper holes and fill weld them this should be a done deal!


Last edited by ckossuth on Fri Feb 22, 2013 6:59 am, edited 2 times in total.

Top
 Profile  
 
PostPosted: Wed Feb 20, 2013 9:35 pm 
Offline
Site Rank - Captain

Joined: Mon Nov 26, 2012 9:43 pm
Posts: 88
Location: Rolla, Missouri
The new hatch is supposed to arrive tomorrow (providing we don't get iced in over the next 24 hours). The Hobie hatch, with its two piece frame looks like it's built like a tank. This should only help tie in all four sides of the hole opening once it's gooped and screwed into place. If I feel the floor needs more support I'll modify it accordingly.

Once again, thanks for the support. I love being part of this community!

Carl


Top
 Profile  
 
PostPosted: Thu Feb 21, 2013 7:44 am 
Offline
Site Rank - Deck Hand

Joined: Sat Feb 16, 2013 6:28 am
Posts: 4
Very impressive work.


Top
 Profile  
 
PostPosted: Thu Feb 21, 2013 8:17 am 
Offline
Site Rank - Admiral

Joined: Mon Apr 16, 2012 12:58 pm
Posts: 155
If all of this works and holds up you need to look at going into business!!! That's some serious mod work and makes it look like ANYTHING is capable with a plastic welder and "a little bit" of skills!!

Looks fantastic so far and I can't wait to see the next installment. I'd love to have a flat floor in my 2012 PA14 but there's no way I would ever try this one personally!!


Top
 Profile  
 
PostPosted: Thu Feb 21, 2013 6:29 pm 
Offline
Site Rank - Captain

Joined: Sun Jan 20, 2013 12:11 pm
Posts: 37
Shimanoman wrote:
VERY IMPRESSIVE!!!


+100 - Great work


Top
 Profile  
 
PostPosted: Thu Feb 21, 2013 10:35 pm 
Offline
Site Rank - Captain

Joined: Mon Nov 26, 2012 9:43 pm
Posts: 88
Location: Rolla, Missouri
Here comes the home stretch. The hatch arrived.

Image

Traced the cut out. The hatch is going to get into the scuppers a little. I'm not worried. I have a solid plan.

Image

Image

These are the bottom of the rear bungee wells. Since the new hatch has a bottom flange these gotta go.

Image

The Dremel Multimax takes care of them nicely.

Image

The inside lip of the hatch sets 1" below the top of the floor. I've made cuts to the scuppers to allow for this.

Image


Last edited by ckossuth on Sun Feb 24, 2013 12:06 pm, edited 1 time in total.

Top
 Profile  
 
PostPosted: Thu Feb 21, 2013 10:41 pm 
Offline
Site Rank - Captain

Joined: Mon Nov 26, 2012 9:43 pm
Posts: 88
Location: Rolla, Missouri
Remember these...

Image

They just found a new home.

Image

Tacked in.

Image

Welded.

Image

This part took some time. I filler welded both scuppers. This gave back some strength and gave the inside lip of the hatch a strong vertical spot to sit.

Image

I had to cut the bottom hatch flange into two seperate pieces. This could not be avoided due to the scuppers. After everything is gooped and through bolted with fender washers it will be very strong. Check out how beefy this part is built.

Image

Almost time!

Image


Last edited by ckossuth on Fri Feb 22, 2013 1:12 pm, edited 3 times in total.

Top
 Profile  
 
PostPosted: Thu Feb 21, 2013 10:47 pm 
Offline
Site Rank - Captain

Joined: Mon Nov 26, 2012 9:43 pm
Posts: 88
Location: Rolla, Missouri
And there you go!

Image

Image

Inside.

Image

Here's a good view of the inside lip sitting on top of the scupper. This thing is crazy solid!

Image

Bet you've never seen this model PA before...

Image

Image

Here's my old foot pads. They came off clean and the adhesive was in real good shape. I put them on waxed freezer paper so they'll peel right off when I'm ready to put them back on.

Image


Last edited by ckossuth on Fri Feb 22, 2013 12:14 am, edited 1 time in total.

Top
 Profile  
 
PostPosted: Thu Feb 21, 2013 11:01 pm 
Offline
Site Rank - Captain

Joined: Mon Nov 26, 2012 9:43 pm
Posts: 88
Location: Rolla, Missouri
Image

After recutting the pads. I cleaned the floor with alcohol. I used my heat gun to warm up the area. This really helps the adhesive re adhere.

Image

Image

Image

I cut a piece of the rubber workout mat into a rectangle and made cuts at all four corners so when you fold it up it's basically a flexible box. It's good size. It follows the inside path of the front 6 scuppers. I put this in the hold so it keeps everything in place. Right now I have 5 plano boxes and other misc. gear. It will hold more.

Image

I've got plenty of material left just in case I pull a Titanic and hit an iceberg! :lol:

Image

I've really enjoyed doing this project. I hope you guys enjoyed it too. The floor of my PA is stronger now than originally. It's gonna be great!

A little tip on welding plastic. I prefer this method but whatever method you choose, the weld MUST penetrate the entire thickness of the material in order to create a durable weld. You can make a weld look pretty on the surface, but if it doesn't go all the way through you can't achieve maximum strength. After you run a weld feel the underside. If it's smooth, you have not gone deep enough. You should feel some slight distortion where the plastic melted all the way through. Practice on scrap pieces (say a 5 gallon bucket) to get the feel for it. Then when you weld an area where you can't reach the backside you'll know it's good. Let your heat source do the work for you. Don't force it. Good Luck!

To everyone who said this was impossible, thanks for the challenge! :D

Carl


Last edited by ckossuth on Sun Feb 24, 2013 12:12 pm, edited 6 times in total.

Top
 Profile  
 
PostPosted: Fri Feb 22, 2013 12:28 am 
Offline
Site Rank - Captain

Joined: Thu Mar 08, 2012 8:26 pm
Posts: 30
What an amazing project. You are very talented and creative. Thank you for sharing.


Top
 Profile  
 
PostPosted: Fri Feb 22, 2013 6:30 am 
Offline
Site Rank - Deck Hand

Joined: Sat Feb 16, 2013 6:28 am
Posts: 4
I can tell you we are going to be talking when I start doing mods. Need to learn a bit more about that plastic welding. Nice work sir.


Top
 Profile  
 
Display posts from previous:  Sort by  
Post new topic Reply to topic  [ 72 posts ]  Go to page Previous  1, 2, 3, 4, 5  Next

All times are UTC - 8 hours [ DST ]


Who is online

Users browsing this forum: paulwinkel, Yahoo [Bot] and 7 guests


You cannot post new topics in this forum
You cannot reply to topics in this forum
You cannot edit your posts in this forum
You cannot delete your posts in this forum

Search for:
Jump to:  
Powered by phpBB® Forum Software © phpBB Group