Project: Trojan 10 Meter Express

Natchamp · Post by **Natchamp** » Mon Nov 28, 2011 8:59 am

Hey guys,

Got one more project done to check off the list. I installed all new seacocks. Slowly but surely the list is getting smaller, but working on boats is a lot of work! cheers.

gettaway · Post by **gettaway** » Mon Nov 28, 2011 10:29 am

nice job!
did you make the backing plates?

Natchamp · Post by **Natchamp** » Mon Nov 28, 2011 11:01 am

Thx, yes I made the backing plates out of 3/4" marine plywood. I used my cnc machine to route out the bolt head pockets. Then I epoxied them all up. I used 5200 on the backing plates to the hull, and 4200 on the thru-hulls and seacocks.

Natchamp · Post by **Natchamp** » Sun Jan 08, 2012 11:21 am

Hey guys,

Havenâ€™t posted in a while so I thought Iâ€™d give you an update. Iâ€™ve been working on finishing up the engine bay, installing the new exhaust hoses, etc. I got the generator put back in and all plumbed up. I just finished running all the new fuel lines and filters, etc. and tying up all those little loose ends. Since Iâ€™ll soon be ready to start the engines I needed to fix the exhaust ports on the hull. I wanted to do this since everything is nice and dry and wonâ€™t be as soon as I start running things. So, this update is to show what I did for the exhaust ports on the hull.

This is what I started withâ€¦..yuck!

I cleaned and sanded the hullâ€¦.

Designed and machined some ports to bond onto the hull. I added some grooves to help facilitate good bonding and some type of a mechanical holdâ€¦â€¦.

Here is a video link of machining them. Machining acetal has a certain sound pitch to it that evidently doesnâ€™t go well with my phone microphone, it doesnâ€™t actually sound that horrible when machining.

http://www.youtube.com/watch?v=y7MkIAzc ... e=youtu.be

I used 5200 to bond all 18 of the inâ€¦.

Big D · Post by **Big D** » Sun Jan 08, 2012 11:41 am

Nice. Hey guys, I know a great guy that does CNC work cheap

rossjo · Post by **rossjo** » Sun Jan 08, 2012 11:44 am

Nice job !

Mike Kulp · Post by **Mike Kulp** » Sun Jan 08, 2012 12:56 pm

Very nice job, I think that Trojan has found the right owner. I have always loved Trojans and especially the International series since I grew up in Lancaster county near the Trojan plant. It does my heart good to see people fix them up and keep them running but in your case you take it a step further and have done a exceptional job, keep the pictures coming.

RWS · Post by **RWS** » Sun Jan 08, 2012 4:16 pm

Wow, really nicely done.

Quality work that you cannot BUY at a boat yard, that's for certain.

In addition to the obvious advantages one huge benfit of the side exhausts is the SOUND.

When a meter boat with these exhausts (sorry mid-cabin boys) is motoring along the canal or coming into the marina it's "sound" is immistakeable.

Sadly, I lost a small portion of that component with the upgrade to the turbodiesels as the turbo by it's very nature tends to muffle the sond of each individual cylinder exhausting - it's not easy to tell, nontheless, those 454's with the side exhausts has a great sound.

Something you won't duplicate elsewhere.

You will also have the added benefit of instantly syncing your engines while on plane.

They do sound great!

RWS

P.S. while you're still on the hard, you migt consider repacking your rudder shafts like I am about to do on mine while on the boat lift - not too much fun anticipated.

Natchamp · Post by **Natchamp** » Mon Jan 09, 2012 8:48 am

Big D wrote:Nice. Hey guys, I know a great guy that does CNC work cheap

I prefer "value driven" pricing

Did I tell you about my special Trojan member's discount? Maybe we need a group project of some sort.

Natchamp · Post by **Natchamp** » Mon Jan 09, 2012 8:49 am

Thanks everyone. It sure has been a lot of work and I'm not even done!

RWS,

I had thought about servicing the rudders. A quick look and everything appears to be good on mine but you know what they say.....

You going to take lots of pics so I can cheat off you ?

gardnersf · Post by **gardnersf** » Fri Feb 10, 2012 11:21 am

Thanks for the link to the Mallory Plug Wires. I ordered two sets and will install this spring. Things are looking really great.

yorklyn · Post by **yorklyn** » Sun Feb 12, 2012 2:26 pm

Natchamp I wanted to thank you! Seeing your progress motivated me to get back into my own. Your doing an awsome job!
How much and what kind of prep did you do before painting your engines? what type of paint did you use and what color is that? they look amazing!!
I think I read that you used Bilgekote to paint (looks great by the way) were you happy with it?
Love the work on the exhaust ports!
Keep up the good work!

alexander38 · Post by **alexander38** » Sun Feb 12, 2012 4:47 pm

loved the video I ran a Repair div. in the Navy in Ct. in the mid 80's that would've taken hrs. back then.

Natchamp · Post by **Natchamp** » Sun Feb 26, 2012 8:49 am

Well, here's a good update for you guys. I just finished my custom dash project. It was a lot of work but I'm pleased with the results. I also installed all new gauges including Flowscan Tach's and GPH. I rewired the whole dash, labeled everything, installed all new switches, etc. You get the idea! Below are lots of pics, enjoy.

aaronbocknek · Post by **aaronbocknek** » Sun Feb 26, 2012 8:59 am

holy crap that looks AMAZING!!! i love the control panel. how did you fabricate that? okay, you need to fly to baltimore and help me redesign the one on my tri cabin..... what did you do to the fiberglass and stainless steel in the 'dash board' area? wow.

ATTN MIKE KULP.... are you seeing this?

keep us posted on the progress.
aaron