'73 Kona Resto build

[holorinhal]

With the boat still upside down ,I laid out the Intake hole cutout.
I am doing a setback and I want the biting edge of the shoe as close to the edge of the transome as posible,and the hand hole outside the boat.
First I found the center line of the hull by measuring the distance of the strakes at the rear of the hull.
I measured from the very upper edge of the strakes at the rear.
http://www.***boat.com/image_center/data/640/256.jpg
http://www.***boat.com/image_center/data/640/1103.jpg
http://www.***boat.com/image_center/data/640/515.jpg
I then measured the distance of the two center strakes about 5' foreward of the transom.
http://www.***boat.com/image_center/data/640/319.jpg
http://www.***boat.com/image_center/data/640/416.jpg
http://www.***boat.com/image_center/data/640/613.jpg
I took the distances divided them by half and marked the center line down the keel.

[holorinhal]

I then measured the length and width of the intake.
http://www.***boat.com/image_center/data/640/1119.jpg
http://www.***boat.com/image_center/data/640/1414.jpg
Then from the transom I measured foreward to define the front of the cut out.
http://www.***boat.com/image_center/data/640/1211.jpg
And then from the centerline I laid out the width of the cut out.
http://www.***boat.com/image_center/data/640/714.jpg
http://www.***boat.com/image_center/data/640/815.jpg
Then mark the cut out on the hull.
http://www.***boat.com/image_center/data/640/916.jpg

[holorinhal]

After I got the hole laid out ,I drilled holes in all four corners of the layout and on the center line,with a 1/16" drill bit,I used the holes to transfer the layout to the inside.
I then flipped the boat right side up,transfered the layout to the inside and cutout the hole.
http://www.***boat.com/image_center/data/640/1510.jpg
http://www.***boat.com/image_center/data/640/1612.jpg
http://www.***boat.com/image_center/data/640/1910.jpg
The lines you see around the hole is the outside edge of the intake,where I have to grind to get the intake low enough.
I droped in the intake to test the fit.
http://www.***boat.com/image_center/data/640/1711.jpg
I ground the perimiter of the hole to get the intake deep enough.
http://www.***boat.com/image_center/data/640/491.jpg
http://www.***boat.com/image_center/data/640/522.jpg
I installed the adjustment bolts to get the height in the hole right.
http://www.***boat.com/image_center/data/640/2110.jpg
Then get under the boat with a straight edge.To set the hight of the intake ,in the front make sure no part of the intake hangs below the keel.Then lay the straight edge along the center of the keel to the back edge of the shoe ,where the rideplate ataches. This is very important,make sure the backedge of the shoe is in the same plane as the keel.With the straight edge ,on the keel. the keel and back edge of the shoe shold all be in the same plane.
http://www.***boat.com/image_center/data/640/2310.jpg
http://www.***boat.com/image_center/data/640/292.jpg

[holorinhal]

After makind all the neccesary adjustmente and test and getting the intake where I wanted it ,it was time to make it purdy.
I sanded the intake ,taped off the machined parts and sprayed some primer on it
http://www.***boat.com/image_center/data/640/301.jpg
http://www.***boat.com/image_center/data/640/332.jpg
http://www.***boat.com/image_center/data/640/342.jpg
http://www.***boat.com/image_center/data/640/362.jpg
After priming, I sanded and then laid down some base coat/clear coat.
http://www.***boat.com/image_center/data/640/371.jpg
http://www.***boat.com/image_center/data/640/451.jpg
http://www.***boat.com/image_center/data/640/461.jpg
http://www.***boat.com/image_center/data/640/471.jpg

[holorinhal]

After The paint had dried,I set the intake back in the hole and mocked up the suction housing to make sure I was happy with where the hand hole is positioned.
http://www.***boat.com/image_center/data/640/543.jpg
http://www.***boat.com/image_center/data/640/562.jpg
http://www.***boat.com/image_center/data/640/552.jpg

[holorinhal]

After I got every thing painted and mocked up,its time to stick it.
I taped off the areas I didnt want to get epoxy on.
http://www.***boat.com/image_center/data/640/643.jpg
i reinstalled the jacking bolts.
http://www.***boat.com/image_center/data/640/693.jpg
i reinstalled the shoe.
http://www.***boat.com/image_center/data/640/701.jpg
http://www.***boat.com/image_center/data/640/715.jpg
VERY IMPORTANT! Make sure there are no shims installed right here in the shoe,for installing the intake ,it will make the intake too high above the keel!
http://www.***boat.com/image_center/data/640/722.jpg
Next I taped off the perimiter of the intake hole,for a neat epoxy job.
http://www.***boat.com/image_center/data/640/653.jpg

[jrork]

This is a great thread and you're doing a killer job Hal. I'm learning a ton. Keep it up.......john
ps.......don't you love the acetone?

[holorinhal]

I set the intake back in the hole,with the jacking bolts installed, to reajust all the settings.
I adjusted the front up so that there was NO aluminum hanging below the keel.
http://www.***boat.com/image_center/data/640/5912.jpg
http://www.***boat.com/image_center/data/640/601.jpg
I then laid the staight edge backk along the keel and adjusted the hieght of the shoe to be flush with the keel.
http://www.***boat.com/image_center/data/640/582.jpg
I then measured up,1' from the two strakes at the transome onboth sides of the hull,and staight edged a line across the two points.This line is used to level the intake side to side.
http://www.***boat.com/image_center/data/640/622.jpg
http://www.***boat.com/image_center/data/640/614.jpg
http://www.***boat.com/image_center/data/640/632.jpg
http://www.***boat.com/image_center/data/640/802.jpg
I then removed the intake,being very carefull not to distub the jacking bolts.
I then mixed up the epoxy,on a cardboard sheet and spread it generously around the intake hole and around the mounting flange of the intake.
http://www.***boat.com/image_center/data/640/733.jpg
http://www.***boat.com/image_center/data/640/742.jpg
http://www.***boat.com/image_center/data/640/753.jpg

[holorinhal]

After spreading out the epoxy,I set the intake in the hole and smashed it down tight ,while wiggling it back and forth, to get out all the air bubbles and squeez out the excess epoxy.
http://www.***boat.com/image_center/...intake_036.jpg
I then picked up the excess,and smoothed out the epoxy ,with wet hands,on the top and bottom.
Just as the epoxy was starting to tack up ,I pulled the tape from around the hole perimiter and the intake.
I then rechecked all the adjustments and measurement's.
I checked the centerline alignment and level.
http://www.***boat.com/image_center/data/640/772.jpg
http://www.***boat.com/image_center/data/640/782.jpg
http://www.***boat.com/image_center/data/640/792.jpg
http://www.***boat.com/image_center/data/640/802.jpg
I then rechecked every thing again.Once I was stisfied that nothing has moved and all adjustments were dead nut's on,I put some dead weight on the intake to hold it in position untill the epoxy had cured.I also put a heat lamp on it to help cure ,since the temprature was a little cool.
http://www.***boat.com/image_center/data/640/816.jpg
I let all that set and cure for 24 hours,before removing the weight.
The intake is set !
http://www.***boat.com/image_center/data/640/821.jpg
http://www.***boat.com/image_center/data/640/831.jpg
http://www.***boat.com/image_center/data/640/842.jpg
http://www.***boat.com/image_center/data/640/852.jpg
I will drill and install bolts temporarilly,to flip the boat and then countersink the holes with the boat upside down

[Outlaw]

Great job Hal..... I bet it takes twice as long taking
all those pics.
thanks for posting them