A Florida based 1987 390 Express Restoration

Dr MicroChip

Dr MicroChip

Member
Nov 8, 2010
401
North Florida
Boat Info
1987 390 Express
Engines
3208 Turbo Cats
Hello all. I have been watching with great interest, Pietro's 390 restoration project. I too have embarked on such a project. I inherited my father's very trashed 1987 390 Express. It had been neglected for years and leaking like the dickens - from the top - for a number of years. I had it hauled up to the Ocala, FL area and parked it outside of my "Play House" where I have been working on it for a couple of years.

http://stroboflash.com/searayproject/

Lately I have been restoring the 3208 turbo cats - only 1200 hours but corrosion took its toll. Inside they are perfect.

See my web site. There are a zillion photos of interest to anyone with a 390 express. That's all for now.

DSC_0028.jpg
 
...I was about to go to sleep...now I’ll be spending the night watching your photos!!! Great work on the boat and in documenting it. Keep us posted. :thumbsup:
You had a real big problem with all that leakage!!! Thanks God mine was much dryer... but I have just noticed that I still have some water leaking from the engine room into the cabin underfloor!!! This happens only if I wash copiously the cockpit... :smt013
 
Thank you for restoring a classic and thank you for sharing your experience with us. I look forward to watching your progress and learning from your experience.

:smt038
 
Your dad would be so proud of you. Keep the pictures coming. My brother-in-law has a 1990 390 Express the cabin is almost the same.
 
Thanks for all the positive comments. I upload the photos to my web site so that I can refer to them when it comes time to put stuff back together. Really helpful to pop open a laptop and check how something was before I took it apart.

My dad built his first boat - a 16' kayak - in 1932. I still have it! His second boat was a 50' steel motor sailor which he started building when I was 6 mos old (1953). He finished it in 1958 and we sailed lake Michigan for 15 years, took it down the Mississippi to Florida in 1973. He decided the sailboat was too slow, sold it to some missionary to haul pigs to Haiti, when he was 75 and bought the Sea Ray 390. The last time I actually drove the Sea Ray was in 1994.

Dear old dad was quite the sailor and loved to tinker with his boats. He held over 30 patents world wide (He invented the push button combination lock in 1948) There were a zillion "improvements" to the Sea Ray that I had to deep six. Yes he would be proud of what I am doing. He just got too old to do it himself.

I have been a mechanic (hobby) all of my life. Now I have a dream work shop and am getting ready to retire. What better way to retire than on a great boat like the 390 Express.

Look out Pietro - I am coming after you! The Florida Flash vs the Italian Stallion!

I am almost done with the second Cat engine. I am really in to restoration. The completed engines are really something to see. Better than factory new. Sand blasted every part, epoxy primed and top coated with catalyzed acrylic enamel. Better than factory new. They will look the same 20 years from now. No rust.

My next project is to rebuild EVERYTHING in the engine room, replace the bonding system and verify all the wiring. Sandblast and paint everything. I HATE RUST!!!!!

I have already fixed all the leaks but have to remove all the glass and side windows to re-bed with the correct materials.

Hull painting will come this time next year with the interior work in early 2012. I am in no hurry - heck I only work on it 20-30 hours a week in my spare time.
 
Albert,
You certainly have your work cut out for you. Thanks for sharing it will be fun to follow your progress along the way!
Todd
 
This is AWESOME!! It is incredible seeing your pictures and what you are doing. Those pictures are also a wonderful resource for those of us with the same boat as now we know what's under that panel or in that space etc...
Thanks for sharing!! If I can help with anything.. just yell
 
Pietro and Dr Microchip, fantastic write ups on your projects. I recently became owner of a 1989 390 in very nice condition. Your writings and pics have answered more questions than any manual could. Keep it going and safe boating!
Dr Microchip, what are your plans for the sideboards in the rear deck area. Mine are beginning to give way and I'm entertaining various thoughts on what to do
 
Like Pietro, I am going to use Starboard to make storage areas around the cockpit. Some open, some with doors. I have to completely make new seats so they are yet to be designed but they will be removable in less than 10 minutes so that I can get 100% access to the engines. Engine access is the one GIANT design FLAW when you have 2 turbo Cats stuffed in the hole.

Al
alias: Dr MicroChip
 
If you are going to use starboard remember it moves a lot with temperature changes, so use a lot of screws and bore larger holes for them.

Al, as you are going to replace the infamous wooden seat bases, you should have a look at tobnpr's 390 that now belongs to docofthebay. He made starboard bases with Pompanette seats. Nice!!!


Jeepers, welcome to tha club :thumbsup:

JoSea016.jpg
 
Wow what a project! The work you've done so far looks awesome though!

Good luck and keep the pictures coming!

Doug
 
Many thanks to all of those who looked at my vast array of photos. One of my many loves is photography. If you want to see some non boating photos see my portfolio here:

http://stroboflash.com/byalbert/

Like those Starboard seats! I had Pompanette seats on my 28' Winner FB Cruiser. They were the best! I don't think Starboard is the best idea for seat bases without a lot of structure inside - plus it is very heavy. I am thinking along the lines of all aluminum. Light and strong. Plus it will let me use my new high tech TIG welder to make them.

An off topic question... How in the heck do you embed a photo within the body of a post???

Al
 
Dr MicroChip said:
Many thanks to all of those who looked at my vast array of photos. One of my many loves is photography. If you want to see some non boating photos see my portfolio here:

http://stroboflash.com/byalbert/

Like those Starboard seats! I had Pompanette seats on my 28' Winner FB Cruiser. They were the best! I don't think Starboard is the best idea for seat bases without a lot of structure inside - plus it is very heavy. I am thinking along the lines of all aluminum. Light and strong. Plus it will let me use my new high tech TIG welder to make them.

An off topic question... How in the heck do you embed a photo within the body of a post???

Al
Click to expand...

Nice photography sets there!

I love photography as well. I wish I had more time for it!

Concerning posting photos in replies.... When you're posting a response, at the top of the text box, click on the icon that looks like a mountain (called 'insert image'). Copy and past the url from say photobucket or another hosting acct and it should show up when you submit the post.

Doug
 
Pietro:

I see a common thread here. It seems that in order to have enough "moxie" to restore a 390 Express you have to be an engineer, love tools, drive a classic car and be a photographer. Your photos are fantastic. I am so jealous - the Italian scenery is so beautiful. Florida is mostly just plain ugly punctuated by pockets of natural beauty that has not been bull dozed by some greedy developer.

Can you please tell us again where you got the swim platform? I looked at the web site you posted but did not see any swim platforms. My boat lost the original platform in the Florida hurricanes of 2004. Your platform is so sexy! I love it.

Al
 
Man oh man....I am simply in awe of anyone who is brave enough...and has the dedication and intestinal fortitude to undertake a project like this on their own. I like to "putter" as much as the next guy but this is over the top.

Unbelievable.

Great pictures chronicling your progress Dr....can't wait to see the finished product....all though I guess completion is some time off yet.

The amount of work involved in a project like this is mind boggling.....as is I'm sure the $$$ cost as well. I do understand though that this is more a labour of love for you than anything else. I can only imagine the feeling of pride and fulfillment you're going to feel come launch day.

If you prefer not to say...no prob....but I'm wondering what kind of $$$ investment a project of this magnitude might involve. No doubt substantially more than I paid for the 268 I just bought in August. :grin:

Congratulations on your project so far. Awesome. :thumbsup:
 
Pietro said:
Nice pics, Al!!!:smt038
You did good use of your Nikon cameras!! I also love photography and Nikons, beside my 390 :grin:

Some pics of mine... http://www.flickr.com/photos/pmoon/ not a professionally shot as yours though...
Click to expand...
Awesome photos!! I really don't have the urge to leave this country with all the nonsense happening around the world, but after seeing your pics, I would love to visit! Who knows...if I keep my nose to the grindstone, I might get there someday:huh:


Awesome project Doc! We do the same thing with luxury buses but not quite on your scale :thumbsup:
 
The major expense of this project is in the engines. They were internally perfect but externally trashed. I will have about $15K invested in the restorations of both engines. I do all the work myself in my shop - next to the boat. The CAT dealer is only 10 miles away so getting parts is a breeze. Labor on the engines is about 150 hours each. I work at home and schedule my boat work during the Florida winter season when the weather is perfect. In the summer I work at my real job - software developer.

I figure another $15-25K to finish off the interior, paint the hull and to rebuild/restore all the mechanicals. Don't forget - I inherited this boat so it cost me $0 up front. To purchase a new diesel powered 40 footer would run about $600K so a $30K -40K investment is not bad. My 18 foot ski boat cost me $20K!! I can buy a lot of diesel fuel for the $550K difference!

Al
 
Well Doc...as I said....I suspect this is more a labour of love for you than anything else considering the boats history and from where and how you acquired it.

There's little doubt though that for a possible $30-$40K investment...hell...even if it gets up to $50K by the time all is said and done....you're going to have one hell of a lot of boat that you can certainly take a great deal of pride in.

Great stuff and best wishes. :thumbsup:
 
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