2003 Prostar 209 Project

[46Chief]

I was looking for a 10k running boat, this popped up within a tank of gas road trip, so I went and looked. I felt confident for the price, we will ski behind it sometime in May.

http://i169.photobucket.com/albums/u216/46chief/Ripple/NJparkingprofile_zps72183436.jpg

Hull is in pretty decent shape.

Interior not too bad.
http://i169.photobucket.com/albums/u216/46chief/Ripple/filthycarpet_zps879b0d38.jpg

I've only found a couple tiny slices in the rear deck but at least there are no tears or busted seams. I'm hoping the carpet will wash out. The vinyl on the coaming pads is heavily stained not sure if it will clean up. I hope I don't have to replace the carpet, if it doesn't clean up I'll replace it with gray next winter.

Unfortunately this boat has a major issue.
http://i169.photobucket.com/albums/u216/46chief/Ripple/majorissue_zpscd40db22.jpg

Probably going to end up with a complete repower. The intake manifold and heads are plugged, it was a seawater boat so there is a fair amount of corrosion throughout the boat. It does have new exhaust manifolds. I have some time to get it cleaned up before ski season, or just ride behind my buddys 197TT

[Table Rocker]

It looks like a great opportunity on a beautiful boat. Is that engine Indmar or the MerCruiser that was found in some Sammys?

[Bouyhead]

Was looking for a 10k running boat, this popped up within a tank of gas road trip so I went and looked. I felt confident for the price, we will ski behind it sometime in May.

http://i169.photobucket.com/albums/u216/46chief/209sideview_zps6c49d87b.jpg

Hull is in pretty decent shape.

Interior not too bad.
http://i169.photobucket.com/albums/u216/46chief/filthycarpet_zps879b0d38.jpg

I've only found a couple tiny slices in the rear deck but at least there are no tears or busted seams. I'm hoping the carpet will wash out. The vinyl on the coaming pads is heavily stained not sure if it will clean up. I hope I don't have to replace the carpet, if it doesn't clean up I'll replace it with gray next winter.

Unfortunately this boat has a major issue.
http://i169.photobucket.com/albums/u216/46chief/majorissue_zpscd40db22.jpg

Probably going to end up with a complete repower. The intake manifold and heads are plugged, it was a seawater boat so there is a fair amount of corrosion throughout the boat. It does have new exhaust manifolds. I have some time to get it cleaned up before ski season, or just ride behind my buddys 197TT

Lucky dog!! I saw that posting on craigslist but was to late!! Not too many project boats in the tri state area to choose from. You wanna sell it;)

[Jerseydave]

Nice project Chief! Where in Jersey did you find that?

Re-power would be the best way to go......I'm sure it's been ridden hard and put away salty! :D

[mikeg205]

Nice project Chief! Where in Jersey did you find that?

Re-power would be the best way to go......I'm sure it's been ridden hard and put away salty! :D

That comment the picture of the motor above and Cloaked's hose picture should have it's own sticky thread...lol :D

[46Chief]

Levittown,PA. I had to drive across the river to say I've been to Jersey:)

I think it's an Indmar. Not sure though how do I read the VIN#?

Wondering if a guy could get a good deal on an Ilmore repower.

[mikeg205]

2003 indmar 350 vortec TBI or MCX? Others here will know better. In 2003 6L and 8.1L available... wow 8.1L that's a bunch of power.

user manual - http://www.mastercraft.com/files/manuals/2003_OwnersManual.pdf

http://mastercraft.com/teamtalk/showpost.php?p=160875&postcount=32 to read hull ID.

ilmore repower? pricey... you may want to check with www.michiganmotorz.com unless price is not an issue at all :)

[46Chief]

Ilmore power is a pipedream, they look pretty darn cool

http://www.ilmor.com/user_area/content_media/5-7-1.jpg

[mikeg205]

Ilmore power is a pipedream, they look pretty darn cool

http://www.ilmor.com/user_area/content_media/5-7-1.jpg

Why a pipe dream cost? as someone once told me - it's only money...:uglyhamme:uglyhamme

When I cleaned up and painted my power I was thinking of how to make a doghouse that shows off the engine... everything has its trade-offs. :) I guess that's why I have a 1995 Prostar. New Prostar - did not want to give up lifestyle - doh!

There's always the lottery...lol.. ;)

Check www.crashedtoys.com - depending on what your looking for...maybe someone trashed a hull leaving an engine waiting for your ride.

[02ProstarSammyD]

It looks like a great opportunity on a beautiful boat. Is that engine Indmar or the MerCruiser that was found in some Sammys?

Mine is the only sammy I've actually seen come with a merc. Wonder how many there actually are.

I saw you put one in it though lol. Should turn out to be a nice boat. I've been reworking one for about 2 years so if you need anything let me know. I prob have more 209 spare parts in my garage than can be found in any parts dept

[46Chief]

Can't figure out what the D is in the engine code and I don't have the injection system or cover to tell.

Hull ID# is: MBCDTMA2E202

[mikeg205]

I have a confusing designation in my hull Id too. Call MC they should be able to tell what was there.

[02ProstarSammyD]

Can't figure out what the D is in the engine code and I don't have the injection system or cover to tell.

Mine has it too. Would guess Duval

[CruisinGA]

Sorry for the threadjack- 02sammyD- what's the rational behind your boat having a mercruiser? Do you have a thread anywhere with pics/details?

[02ProstarSammyD]

Sorry for the threadjack- 02sammyD- what's the rational behind your boat having a mercruiser? Do you have a thread anywhere with pics/details?

Any boat out of the duvall school had to run a merc due to a contract disney had. I haven't done a ton of investigating into the boat to be honest. It was sold out of orlando, then to rambo, then to the PO, then to me. The hours have matched down the line and the install is fairly clean besides the fact the use of faria gauges for temp and rpm so my assumption to this point is that its just an extremely rare boat. I've heard numbers of 10-30 total made. I can post some pics if you want. The engine is an 02 mag ski

[46Chief]

D is for Duvall...DOH! Many surprises already in this project.

I e-mailed MC to see if I can get clarification on my Hull ID. Hope they respond today.

Anyone want to post an engine pic of their SD?

[02ProstarSammyD]

I can try and pop some later today if I can get out of the office

[46Chief]

Was able to work on it a limited amount this weekend, mostly just started removing engine parts, and doing a little investigating. I removed the wire loom off the back of the engine and found that the bellhousing is stamped Indmar, I also found a small sticker on the oilpan that said LTR. I'm thinking this is an indmar LTR.

Removed the platform brackets, these are pretty aren't they? Look real close you can see the hull has a rubbr undercoat, maybe an antifouling paint. it doesn't look bad so it's at the bottom of the squawk list.

http://i169.photobucket.com/albums/u216/46chief/Ripple/platformbracket_zpse1745a7a.jpg

I'm curious why there's a chunk of cement bolted to the rudder.

http://i169.photobucket.com/albums/u216/46chief/Ripple/barnacle_zps56453db7.jpg

The vinyl is pretty dirty in this boat, it is also worn. This wouldn't clean off with a have heavy application of soap and hot water. I thinking next winter we'll tackle interior replacement, since there are only a few minor holes and a couple tears in the upholstery. Has anyone tried to to dye or fix small tears and cracks with success?

http://i169.photobucket.com/albums/u216/46chief/Ripple/vinylcoaming_zps295d8ef2.jpg

[VTJC]

The ‘cement’ is probably a zinc sacrificial anode on the rudder, to save the rest of the running gear. Looks like that poor boat slept in the salt water. Glad it’s getting a new life.

[CC2MC]

Wow. Nice find. Can't wait to see the progress. Hope you have some good luck with finding an engine for her.

[milkmania]

The ‘cement’ is probably a zinc sacrificial anode on the rudder, to save the rest of the running gear.
agreed, or it would look just like the platform brackets

[mikeg205]

Some larger vessels actually run a bit of current to the anode for added protection... cool that that works.

[02ProstarSammyD]

hey man here are the pics of the merc. Sorry they aren't great. Was mounting new shelves in the garage all weekend so sacs and vests were in the boat. If you want I can get some better pics later.

http://www.mastercraft.com/teamtalk/picture.php?albumid=500&pictureid=4876

http://www.mastercraft.com/teamtalk/picture.php?albumid=500&pictureid=4875

What interior pieces are beyond scrubbing? I just happen to be redoing my entire interior this winter and may have some of what you need at a bargain price.

[46Chief]

Thanks for the offer and pics, I wasn't sure what engine I had, but I think I figured it out this weekend.

I am considering a sweet deal on a Mercury Bravo repower and searched through the engine thread and didn't see any Mercs or LTR's in the thread. I still need to talk with someone on the phone to see what I would be getting into with trying to adapt the current harness to the Merc. All I know is the round 7 pin plug looks the same at this point.

For the most part the stitching is solid there are only a couple small tears that may be able to be fixed. I don't think the interior will clean up, I haven't order the Babes cleaner yet, but will give that a try and probably run as is, this season and hope that is the winter project for next year. Surprisingly the vinyl is mostly intact considering the reputation of the early 2000 model years reputation for poor quality vinyl.

[02ProstarSammyD]

What engine was in it?

[46Chief]

Indmar LTR 1:1 is what the sticker on the oil pan I don't have the intake or anything yet.

Is the panel behind the engine cover that covers the mufflers and props haft bolted down? I can't get it loose or find any fasteners

[CruisinGA]

Not bolted in my '02 X9. Friction fit due to carpet.

[CCAnderson]

rear panel is friction fit. take off the gas struts and then pull up at the rear of the hatch with the seat out. darn thing is fairly heavy so be careful.

[CruisinGA]

The hinges that attach the engine hatch base to the rear panel broke on my X9 before I got it.
I have not fixed them because it makes things much easier to be able to lift the entire hatch off and the rear panel separately.

[02ProstarSammyD]

The hinges that attach the engine hatch base to the rear panel broke on my X9 before I got it.
I have not fixed them because it makes things much easier to be able to lift the entire hatch off and the rear panel separately.
Reply With Quote

haha I'm in the club too

Like the others said it should lift out. If its a real pita lift the entire hatch back, grab the edge by the motor and pull up. Once it starts coming out it will pop right out.

Also just an fyi. Sell the tranny and boom. Any idea how the trans is on the current setup?

http://www.ebay.com/itm/2005-5-7-Liter-Indmar-Engine-with-ZF-Hurth-1-to-1-Transmission-very-low-hours-/130831652377?pt=Boat_Parts_Accessories_Gear&hash=item1e762c9619&vxp=mtr

One problem I see coming is electrical for sure. Now get some progress pictures coming!@

[46Chief]

My engine hatch screws pulled out with very little effort. that dog house is heavy. I guess the front latches hold it in place for you guys then.

I love the look of the anodized red on the MCX, not sure I'd buy that engine if a clear history was provided. The dataplate on the transmission has black overspray, makes me wonder what they are so haphazardly hiding.

Exploring the possibility of a Mercury Bravo repower, I made a couple calls this week, Mercury wasn't alot of help, I'll do some more on that Friday...love working 4/10's. I also talked with an old ski buddy who owns a boat shop in FL, he's encouraging me to go with a PCM repower, bring the boat to him then we can remove the antifowling paint buff out the hull and spend some time getting things done right by somone who knows ski boats... But it's a 14hr tow. Would be nice to have peace of mind for the ski season and not have to tinker 2hrs for every hour of skiing.

As far as physical progress I removed a few more things while the weather was nice yesterday #needashopformyboat.

Drivers seat is frozen to the tracks by rust. I got under it and freed the latch mechanism but couldn't get it to slide. I was able to remove the bolster, so I can remove the bracket and clean it up.
http://i169.photobucket.com/albums/u216/46chief/Ripple/Drierseat_zps30a53b6f.jpg
http://i169.photobucket.com/albums/u216/46chief/Ripple/Boosterseatbracket_zpsf01f3d71.jpg
Also removed the platform brackets to get them in line for a date with the paint stripper and blast cabinet.
Most of these brackets have pitting, I feel I can live with that and just cover it with a good protective coating of paint. Suggestions are always welcome, I was thinking epoxy. I don't really want to pay for powder or anodizing.

[Bouyhead]

Do you have access to a glass beader/blasting cabinet? If your going to do most of the work yourself it might be a good investment. If you blast most metal surfaces clean follow with a good marine or self etching primer,(found in a spray can) and good quality paint will work for most of your parts.

Just read your post again about the blast cabinet:o I've had good luck with epoxy paint in the can as well as shooting stuff out of the gun.

[02ProstarSammyD]

^not a bad idea but I've found in the past I always needed larger items blasted. Find a local powdercoater and you can prob bribe him on the cheap to blast your parts. I agree that some self etcher and rattlecan will help ALOT on the parts and prob save you a ton of money. My seat was frozen similar to yours and some pb loosened it right back up.

Merc isn't a help with anything and has been my only beef with them. I've had a pain getting some parts and part numbers for past needs which was irritating to say the least. The 555 is a nice lil system though and makes problems easy to fix along with the lp and hp fuel pumps being a big + instead of the in tank.


I love the look of the anodized red on the MCX, not sure I'd buy that engine if a clear history was provided. The dataplate on the transmission has black overspray, makes me wonder what they are so haphazardly hiding.

Not sure thats overspray or just the crappy chrome sticker peeling. I'd bet my money it being just a crappy sticker. Also you aren't going to get a lot of history on these engines unless you go new. Not sure the condition of your engine but have you considered a new block/risers?

as for the brackets I wouldn't bother powdercoating. One chip and it will start peeling. I used standard rustoleum on mine and haven't had an issue in 3 years.

Also just an fyi for your carpet. Throw some laundry detergent (non bleach) in that thing and scrub a dub dub. Run it to the 2 dollar power wash and power it out. At least then you'll know if you are going to have to replace it or not. Not sure how you like the tan in there lol. Personally I've rid my boat of all the factory light grey paneling and went to black. Would look super sharp with some non tan carpet and black that bad boy out.

Also guess I'm curious to the level you are trying to get this thing to. If you are going full out restore on this thing thats freaking great but from what I've picked up sounds like you are trying to get a budget ski boat. If thats the case I'm not sure how much I would mess with the bottom paint. There could be some hidden demons under that paint

[Jerseydave]

Chief, I'm 20 mins from Levittown PA. If I had known you were that close I would have bought you a cold one! :)

LTR 330 hp Indmar would be my guess. I'm sure you could get a direct replacement engine. Or you could try Jasper or ATK and see what they offer. www.part-man.com sells Mercruiser engines I think.

Rep, that's bottom paint on her which will slow it down. You can soda blast it off and maybe save the original gelcoat finish.....it's a gamble, you won't know for sure until you try.
And yes zinc on the rudder, maybe on other places too (strut, tracking fins?) Salt kills.

[46Chief]

Made a little progress between work and snowstorms, fortunately I've had a couple nice weekends this month.

http://i169.photobucket.com/albums/u216/46chief/Ripple/SD_Profile_zps595112e2.jpg

http://i169.photobucket.com/albums/u216/46chief/Ripple/sd_snowdrop_zps6be8527a.jpg


Started with this earlier this month:
http://i169.photobucket.com/albums/u216/46chief/Ripple/majorissue_zpscd40db22.jpg

http://i169.photobucket.com/albums/u216/46chief/Ripple/topend_zps96a08f5f.jpg

Now I just have to figure out where I am going to get this thing hoisted out.

At this point I am thankful for all the cad plated bolts, I was sure I was going to be calling the snap on guy for a set of EZ outs, due to all the rusty frozen bolts I was going to encounter. Thankfully MC and or Indmar used cad plated bolts and stainless hardware on mostly everything, so It's coming apart easily. Just look at the coupler I thought it was pretty much welded together by corrosion. the bolts came out nicely and I just bumped it loose. I did put a couple heavy applications of kroil penetrating oil on everything.

http://i169.photobucket.com/albums/u216/46chief/Ripple/bilgegine_zps7eb8ed5e.jpg

Found this, I guess all the dataplates from Hurth are installed before the the painter haphazardly masks it off.

http://i169.photobucket.com/albums/u216/46chief/Ripple/tmxn_tag_zpsb3224a5b.jpg

Got the mufflers out, and removed whatever was screwed down that was nasty and corroded. Unfortunately my camera crapped out and it's too cold to pull that cover off. instead of pics of my nasty bilge, I have some to show of my archeology expedition

http://i169.photobucket.com/albums/u216/46chief/Ripple/towercrack_zps2dc5cd38.jpg

Hopefully I can get another year of use out of this tower with the help of a welder.

http://i169.photobucket.com/albums/u216/46chief/Ripple/aitrim_zps9b9c7929.jpg

The clearcoat and corrosion has made the aluminium trim plates kind of ugly, I'll probably just wrap these in vinyl or paint them gray.

http://i169.photobucket.com/albums/u216/46chief/Ripple/frontspkr_zpsa3e82c69.jpg

Something else I didn't account to spend more money on. Stereo is at the bottom of my list of things I require in a boat, I'd remove it, if it wasn't for the gaping ugly hole in the upholstery.

I was able to make some forward progress making things pretty.

I was able to clean up alot of stainless hardware, mostly hose clamps and all the screws holding brackets and interior pieces down. look closely you can see the pretty bolster brackets in that pile.
http://i169.photobucket.com/albums/u216/46chief/Ripple/P1221492.jpg

Debarnacled the platform brackets.

http://i169.photobucket.com/albums/u216/46chief/Ripple/P1221502_zpsf19e41ad.jpg

Not sure when I'm going to tackle the platform, but included the pic for before and after bracket pics.

http://i169.photobucket.com/albums/u216/46chief/Ripple/teak_zps8d77a80d.jpg

Waiting for the weather to warm up to finish pulling the motor and transmission, propshaft etc.... Then I can give the carpet and bilge a proper bath.

[46Chief]

Had a little time and nice weather before work, was able to pull out the ballast pumps and see what surprises may com.

http://i169.photobucket.com/albums/u216/46chief/Ripple/Ballast_zpscae65bb2.jpg

Adding another 200.00 dollars to the spreadsheet, the back plate of the pump has completely corroded away. the other one doesn't look bad, might as well order another impeller and o-ring.

http://i169.photobucket.com/albums/u216/46chief/Ripple/sterringcble_zps65abbd9d.jpg
I can't wait until I can get the engine and tranny removed, so I can douche this bilge in proper fashion. Then I'll remove the rudder the platform brackets and get that all restored back to clean and shiny.

[Lumbergh]

Sad to see such neglect. Some people are just savages.

[Ironhorse]

Great work and thanks for including the pics. Keep it up!

[46Chief]

Took apart the Jabsco ballast pumps to see what they are made of.

If anyone has a non working spare for parts, I'll trade for beer and shipping.

http://i169.photobucket.com/albums/u216/46chief/Ripple/b-motors_zps00540e3d.jpg

Started to clean up the steel motor housing.

Does any one know if will affect motor operation if I powder or plate the housing?

http://i169.photobucket.com/albums/u216/46chief/Ripple/motorhousing_zpsb57184fc.jpg

Got this cleaned up, I may have an extra one or two depending depending if I can salvage at least one pump. I haven't figured out if I can find that seal to replace it.

http://i169.photobucket.com/albums/u216/46chief/Ripple/ballast-pump_zps4743cfe9.jpg

Got these pulled off, was surprised by the weight of the rudder.

http://i169.photobucket.com/albums/u216/46chief/Ripple/drtyrudder_zps41a5d4c5.jpg

http://i169.photobucket.com/albums/u216/46chief/Ripple/dirtyprop_zps344c4f0e.jpg

http://i169.photobucket.com/albums/u216/46chief/Ripple/drtytiller_zps7efef79a.jpg

Cleaned up nicely

http://i169.photobucket.com/albums/u216/46chief/Ripple/bladerudder_zps63fed95a.jpg

http://i169.photobucket.com/albums/u216/46chief/Ripple/btrip_zps97da5903.jpg

[barefoot]

Chief...what are you using to clean the components?

[46Chief]

Chief...what are you using to clean the components?

I scrub everything with hot water and dawn dish soap to remove the grease. You'd be surprised what a week will do for nasty, neglected, corroded parts soaking in a highly concentrated solution.

Then I strip with media:

Plastic beads for the painted parts like the platform brackets.

I'll also give it a quick once over with dry glass bead to shine steel brackets up.

http://i169.photobucket.com/albums/u216/46chief/Ripple/shifterlnkge_zpsa9b9f0e9.jpg

Wish I had access to a HD soda blaster.

[02ProstarSammyD]

Looking good man. Only 5000 more things to do. I'll check in the garage but I might have another set of components you can have for the stereo. If not you can get a cheap set of kickers or polks for sub 100 bucks to replace the 6 1/2"s

[fskof]

Can't figure out what the D is in the engine code and I don't have the injection system or cover to tell.

Hull ID# is: MBCDTMA2E202

If you gave a dealer that vin number they should be able to tell you what that boat had when it left the factory. If the dealer wont then try Mastercraft.

By your hull id it looks like you have a 2002 and not a 2003. The last two numbers are the model year.

Great project you have on your hands. I have a 2003 209 with the MCX so if you have any questions just ask and I will try to help

For the carpet I would rent a carpet cleaner and use some oxy clean on the stains. I think it can be saved and you will save some $$$ by not needing to replace it!

You also have a heater. How bad is the heater coil? It should be located under the front seat in front of the dashboard.

[46Chief]

Yep it's an 02, not sure how came up with 03. I pulled the heater already, the hoses were cut, so I suppose it's junk, I haven't tried to tear it apart yet, I figure when I'm ready I'll see if i can flow water through it, give it a little pressure test and see where I'm at. Darn things are too simple for what they charge for them, kind of think like the ballast pumps you just can't replace or repair the broken parts inexpensively. I really like having a heater in the boat, but all funds go into gettin the boat running and on the water so I can use it this summer accessories like stereo, ballast and heat will have to wait.

Thanks for the offer 02ProstarSammyD, I might take you up on it, but will probably just buy new. I should check to see if the head unit is any good...Most likely not, considering that pretty much all the accessories I have found are worn out and broken.

I keep telling myself not to curse the previous owner about how he treated this boat, because I wouldn't have this project and be into a the boat I was going to work up to. I am cursing the dealer for not selling them a closed cooling system on a known saltwater boat and selling them a terrible trailer.

I also think it's a testament to MC build quality that the hull is as good of shape as it's in considering the abuse and neglect.

When someone asks that question why not put a non-marine longblock or shortblock, my answer would be because all the fasteners and brackets involved are stainless or cad plated, not to mention the other corrosion proofing that we don't know. I thought for sure I'd be buying a broken,stripped bolt extracting set from the snap-on guy by now. Only have had some sticky stainless screws from the interior parts.

[02ProstarSammyD]

Thanks for the offer 02ProstarSammyD, I might take you up on it, but will probably just buy new. I should check to see if the head unit is any good...Most likely not, considering that pretty much all the accessories I have found are worn out and broken.

good b/c the component set I have left is a 5 1/4 set. Nickspi is getting my 6 1/2"s unfortunately. Still need to get that merc in there. Better hurry up on 45 days til season starts for you guys I imagine!

[02ProstarSammyD]

I require updates here!

[46Chief]

I require updates here!

Worked through the weekend at my pay the bills job... gotta get that OT to pay for the all the parts I'll need.

I was able to spend some quality time with my boat.

Used a sawzall to cut the drivers seat from the pedestal.

Then grabbed a hammer and some more penetrant to see if these tracks will come of.
http://i169.photobucket.com/albums/u216/46chief/Ripple/Seat_zps6708f3de.jpg

Nope....Need a bigger hammer, or just open the latch.

http://i169.photobucket.com/albums/u216/46chief/Ripple/seathammer_zps5909035d.jpg

Sorry no after shot but they came out and thankfully the screws came loose.

Just gave it a good soap and water scrubbing to see what I'm dealing with... The rust stains in this upholstery are gonna drive me bonkers. Looking like the seats are going to be able to get me through a season or two before I want to reupholster.

http://i169.photobucket.com/albums/u216/46chief/Ripple/rustseat_zpsa3a3c32b.jpg

Got up too early Saturday to get ready for a long day at work... and do something about this mess.

http://i169.photobucket.com/albums/u216/46chief/Ripple/P2231659_zpsd42c0de4.jpg

Sorry no action shots.... too busy trying to get it out with a sketchy cherry picker and create any new problems.

Made a stop on the way home.

http://i169.photobucket.com/albums/u216/46chief/Ripple/preswash_zpsb6b9a251.jpg

Looking better, hoping to get back into it if it warms up and stops raining to scrub the bilge and carpets hard.

http://i169.photobucket.com/albums/u216/46chief/Ripple/P2231666_zps397b11aa.jpg

Again those rust stains, remember if you have beige carpet and set something steel and rusting on them....your gonna be cussing and spitting and well, you get the idea.

[02ProstarSammyD]

Looking better, hoping to get back into it if it warms up and stops raining to scrub the bilge and carpets hard.

power washer...........

You can rent a steam cleaner and do it but not sure its worth it. I did it on mine for mcocd purposes. Hit the bad spots with la awesome, clothes detergent for the rest. scrub the meh areas and powerwash the rest. Bilge you can fill up with cleaner and the plug on the drive over haha.

[fskof]

Try some oxy clean on the carpet. As for the the rust stains, if the seats are white (hard to tell with the pic) try a little bleach on just the rust spots! Dab a little bleach on a towel or q-tip and rub it on JUST THE RUST SPOTS! DO NOT WIPE THE ENTIRE SEAT WITH BLEACH. It should remove the rust spots or make them less noticeable for the season or two before you want to reupholster them.

[46Chief]

Thanks for the bleach tip, I'll be giving it a shot tomorrow, hopefully I'll get a warm day this weekend to try and do some super scrubbing on the carpet.

No real updates I have the bilge area squeaky clean and have a pretty much all the the parts I've removed cleaned up and ready for paint and plate. I'll post pics of the finished parts soon.

Just around 6 weeks to my goal of being seaworthy and I'm starting to stress, My engine options are slim and expensive. I'm leaning towards re-powering with a brand new PCM engine because I'm told it will work with the analog gauge system and will run w/o a catalytic converter. but that is going to be nearly 10K installed and dialed in.

I have a line on a used 2005 MCX, but I have to convert from analog to digital throttle and gauges add another 2k to a 3500 dollar engine with an unknown history and I'm thinking the reliability of the PCM will be worth the extra money.

If I could find an LTR intake manifold I'd consider a longblock, and piece back the old engine, but that reliability issue of the fuel injection and the prospect of a bunch of NLA parts rears it's ugly stinking head again.

Last but not least I have a 4bolt main 350 block and a set of heads It's tempting to build my self a carburated motor for under 1000.00, but would still have to get the instrument in the dash to function, and I really want to keep the resale value of this boat in the event I want to try something different down the road.

[Ski-me]

Pretty cool project! Is this what the engine is suppose to look like?!? :o

[02ProstarSammyD]

thats just cold

[46Chief]

Thanks I've been wondering that, and yeah a little salt in the wound can be helpfull

[Double D]

Chief, remind us again how this boat got this way? By the shape of everything in the pictures I looks as if it was sitting 50 feet down in salt water for months.... :mad:

[Ski-me]

Thanks I've been wondering that, and yeah a little salt in the wound can be helpfull

Sorry man....wasn't trying to rub any salt in ya! :o

Still, very cool project! :cool:

[Dylan]

Thanks for the bleach tip, I'll be giving it a shot tomorrow, hopefully I'll get a warm day this weekend to try and do some super scrubbing on the carpet.

No real updates I have the bilge area squeaky clean and have a pretty much all the the parts I've removed cleaned up and ready for paint and plate. I'll post pics of the finished parts soon.

Just around 6 weeks to my goal of being seaworthy and I'm starting to stress, My engine options are slim and expensive. I'm leaning towards re-powering with a brand new PCM engine because I'm told it will work with the analog gauge system and will run w/o a catalytic converter. but that is going to be nearly 10K installed and dialed in.

I have a line on a used 2005 MCX, but I have to convert from analog to digital throttle and gauges add another 2k to a 3500 dollar engine with an unknown history and I'm thinking the reliability of the PCM will be worth the extra money.

If I could find an LTR intake manifold I'd consider a longblock, and piece back the old engine, but that reliability issue of the fuel injection and the prospect of a bunch of NLA parts rears it's ugly stinking head again.

Last but not least I have a 4bolt main 350 block and a set of heads It's tempting to build my self a carburated motor for under 1000.00, but would still have to get the instrument in the dash to function, and I really want to keep the resale value of this boat in the event I want to try something different down the road.

That is a heck of a project, but you are definitely doing it right. With the condition of the boat, I'd be surprised if the gauges even still worked. Maybe even the wiring harness has corroded? You might be better off going with the carbed motor, and get to enjoying it.

I realize it's a lot easier for me to spend your money :) However, you might consider verifying that the gauges even still work before you make a repower decision.

Good luck, and I'm looking forward to following your build!

[46Chief]

Chief, remind us again how this boat got this way? By the shape of everything in the pictures I looks as if it was sitting 50 feet down in salt water for months.... :mad:

It was just used in saltwater and never really taken care of... Then it got picked up by a guy who thought it needed a head gasket and somehow lost the intake and set a bunch of nasty rusty greasy parts on the carpet tearing it down.

I'm confident the harness is good and the boat was never under water.

The hot rodder in me wants to build a carbed 383 stroker.

The mad scientist in me wants a Turbo'd Cummins 4bt to run biodiesel.

But the guy who just wants a reliable ski boat this summer prevails and is looking for a solution as close to oem as possible.

[Ski-me]

http://affordablemarinesd.com/stor/engines-for-sale/

http://www.michiganmotorz.com/

[Dylan]

http://affordablemarinesd.com/stor/engines-for-sale/

This place is about 10mins away from my work. If you decide to go with them I can probably swing down there and take a look for you.

[Nelsonjeff79]

As a fellow PS 209 owner I am really enjoying following your restoration project. I actually was going to mention that it would be so cool to put a diesel in it, however if I were repowering this boat for the sake of time and money; wouldn't the TBI injection motor (Indmar Predator) be perfectly suitable?

BTW-I have the same ND Tower, what happened to the weld? Was it damaged from weather or did the weld break?

[fskof]

I love restoration projects like this! Keep posting pics when you have time! You have a great boat there to work on. It will need some hard work and some $$$ but when you are done you will be very happy with the results! It will be worth it when summer get here and your out on the lake with friends with cooler full of cold drinks!

Thanks for saving it :toast:

[fskof]

It was just used in saltwater and never really taken care of... Then it got picked up by a guy who thought it needed a head gasket and somehow lost the intake and set a bunch of nasty rusty greasy parts on the carpet tearing it down.

I'm confident the harness is good and the boat was never under water.

The hot rodder in me wants to build a carbed 383 stroker.

The mad scientist in me wants a Turbo'd Cummins 4bt to run biodiesel.

But the guy who just wants a reliable ski boat this summer prevails and is looking for a solution as close to oem as possible.

There has to be someone here on TT that has a engine or knows someone that has a period correct engine for a good price. Maybe Jim@BAWS can help out?

[46Chief]

Pretty cool project! Is this what the engine is suppose to look like?!? :o

If you are bored you could run out, pull the cover off that motor and snap a couple pics so I can get a better look at what is under it.

My little brother just pulled a 2000 mile roadtrip to pick up this little sweetheart of an X9

http://i169.photobucket.com/albums/u216/46chief/Ripple/spksx9_zps79b3171b-1_zps816af845.jpeg

I went to relax in a cabin last weekend so no real updates, just been trying to convince myself what is the best road to take before pulling the trigger on a motor.

[Ski-me]

If you are bored you could run out, pull the cover off that motor and snap a couple pics so I can get a better look at what is under it.

My little brother just pulled a 2000 mile roadtrip to pick up this little sweetheart of an X9

http://i169.photobucket.com/albums/u216/46chief/Ripple/spksx9_zps79b3171b.jpeg

I went to relax in a cabin last weekend so no real updates, just been trying to convince myself what is the best road to take before pulling the trigger on a motor.

Sorry, I have an LT1 engine...... I found that one on the "internet" :D

[46Chief]

Been doing some MC TT research tonight and found these helpful threads in getting my interior vinyl cleaned up, Going to try the the cleaners Craig used and possibly order some vinyl paint.

Craig's 94 Prostar 190, slight refurb thread (http://www.mastercraft.com/teamtalk/showthread.php?t=29296)

h20ski's Just painted faded red vinyl stripe looks great!!! (http://www.mastercraft.com/teamtalk/showthread.php?t=29118)

[FrankSchwab]

Your clean up jobs are amazing. It's great watching this going on...

It'll be interesting to see if you get a whistle from that hole in the rudder.

[fskof]

Whats the latest with your project?

[46Chief]

Working as much OT on the weekends as I can handle before it gets nice. Hoping to raise enough money to pay cash for a motor.

Engine decisions have been challenging, I made an offer for that ebay MCX with the tranny and the lady accepted. I was pretty excited about the prospect of having an MCX in the boat. Then she changed her mind and re-listed on ebay with a buy it now for 3k, then she raised it to 3500.00 a couple days later, so I said screw it, I have other options for less money. I really liked the idea of making that MCX work, especially since I may need a transmission.

Which brings me to addressing another huge obstacle. I can't get my transmission separated from the block. I know I've removed all the bellhousing bolts and was able to get it to come apart about a 1/2" from the block, and now it seems to be frozen to the flywheel.

Round One: clean up the cakebatter that oozed out of the upside down engine.

Spraying Kroil on it religiously for the last few weeks, and wrestling with it on my motorcycle jack while avoiding dropping it on my foot and breaking toes.

http://i169.photobucket.com/albums/u216/46chief/Ripple/P2271672_zps1206c896.jpg

Cut some wedges out of some scrap 2x4's

http://i169.photobucket.com/albums/u216/46chief/Ripple/P3021699_zps7fd125f9.jpg

Get the heavy hammer and start pounding wedges.

http://i169.photobucket.com/albums/u216/46chief/Ripple/P3171763_zps9360476d.jpg

It's a bit of a challenge to drive a wedge and just make contact with the block and bellhousing, I imagine the flywheel is bolted to the crank and shouldn't stay with the tranny when it pops loose. The only thing I was able to achieve is making a lot of toothpicks and splinters.

Round Two:

I thought it may be more mangeable if I could pull the oil pan and maybe get the crankshaft out. I was mistaken I can't get the rear main seal off because it's a two piece bolt on seal and I can't get to the bolts, obviously designed to be removed w/o a transmission frozen to the crank.

http://i169.photobucket.com/albums/u216/46chief/Ripple/P4071834_zps009e9c4a.jpg

Round Three:

Tired of wrestling with this thing on my floor jack, ponied up a case of Bud and got my buddy to bring me his cherry picker. Made a concoction of acetone and ATF, instead of wasting another can of of penetrant, and let that sit overnight. Hung the thing by the transmission mounts, Cut some oak wedges and some aluminum shims and went at it with the hammer and wedges again. I was definitely able to get some convincing wedgie force on this thing.


http://i169.photobucket.com/albums/u216/46chief/Ripple/P4071829_zps688632f2.jpg

http://i169.photobucket.com/albums/u216/46chief/Ripple/P4071828_zpsee2666f2.jpg

I'm starting to believe it's permanently welded to the crankshaft and will become an anchor for the slalom course.

I'm not ready to give up yet, I'm going to try and get some torch heat on it, my heat gun didn't work, and if that doesn't do it I'm going to cut the mainseal off and then cut the crankshaft and see what I can do from there.

I've already started googling "Hurth ZF 45 CW for sale".

[Ski-me]

Stumbled on this craigslist ad......who knows if they have something for you.

http://jacksonville.craigslist.org/boa/3633063736.html

[VTJC]

you could use this boat: http://www.mastercraft.com/teamtalk/showthread.php?t=53667 for parts...

[46Chief]

It's getting to be that time, dock has been in the water for a week, been out on the SUp a couple times and I still have a empty hull.

Well I did get this in the garage now I'm trying to figure out if I can make it work.

http://i169.photobucket.com/albums/u216/46chief/IMG_6322_zps09ec8c7b.jpg

I need to delete the power steering pump, Figure out how to fuel it, and re wire the volvo 10 pin harness to my Indmar 9 pin.

Trying to decide the best route to delete the PS pump. It would be nice if I could find a factory alternator bracket and routing of the serpentine belt. It looks like I'll be fabricating brackets...Gonna be fun getting the proper alignment on the belts huh?

Any advice on the fuel system?
A. Remove Volvo fuel pumps and filter assy.,and plug in the fuel lines and wiring to utilize the Indmar/mastercraft fuel pickup sending unit pump combo in the tank.
B. Use the Volvo pump and filter system and try and fabricate some sort of pick-up fuel sending unit for the the tank.

Finally, I hate to cut the OEM harness's unless it's the last resort. I would like to find a 10 pin male round plug for the Volvo and make a pigtail with a 9 pin round harness to plug into the existing harness in the boat. I spoke with a tech from ebasicpower but he says there is no such thing as a nine pin harness. I double checked and recounted both and found the tech is misinformed. Indmars harness is a 9 pin. So I am having no luck finding a round female 9 pin and a male round 10 pin, so I can wire them together and make my own adapter. Anyone have a hacked up one with enough wire to make one laying around? I'd trade ya for a power steering pump

[Table Rocker]

What about the accessory mounting from your old engine, could you use it instead?

[46Chief]

That was my first consideration but the the harmonic balancers are different. I'm hesitant due to weight difference. The North Star ignition has the timing wheel and mag sensors that are part of the lower pulley system so it probably makes up for the weight difference. I also was hoping to use the Volvo fresh water pump because the indmar one is in need of a rebuild or replacement. I don't know how they think they are worth a 140.00.

[88 PS190]

Dude in regard to the PS pump. So many options.

Quick and dirty is to just run a loop from input to output and have it recirc. This will waste some HP and some fuel, but save lots of money/time.

Next idea would be that the pulley dimension is all that is sacred, make an idler out of it.

The real stroke of GENIUS. York A/C compressor, with that pulley, make your brackets -convert AC compressor to AIR COMPRESSOR - blow up your toys Dawg.

Third Idea... Water pump - bow mounted water cannon.

Fourth. shop some shorter belts, play with routing, find one that works - run it.

[46Chief]

Air compressor and water cannon.... Now that's some thinking.

May just run the ps pump but want a cleaner solution, and to sell the pump.

[bturner2]

March might have what you're looking for or will make you something that will work right the first time. They've been around a long time and I'd bet they've done boats before.

http://marchperf.com/gallery_chevysmall.html

[zsqure]

Hey Chief, post up pictures of the connectors. Someone on here has to have access to a cable / harness supplier. We may be able to figure out what you need. Look in Digi Key, or Mouser catalogs for the mating connectors. My first engineering gig was a Mfg Engineer in a cable house. Are the plugs Amp, Ampnenol, Weather Pak connectors? A "pigtail" to convert from one to another is a good idea. Like 88 PS190 said use the pulley as an idler. the problem you will have is lubricating it as an idler, or keeping it cool if you use the whole pump. Good luck.