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Old 11 March 2015, 18:10   #1
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Country: UK - England
Town: Whitehaven
Boat name: Pegasus
Make: Zodiac Pro 530
Length: 5m +
Engine: 115hp Merc 4st
Join Date: Oct 2012
Posts: 337
Zodiac Turd Polishing

I figured it was about time I posted my turd polishing project for the last year or so. I bought the boat 2 and a half years ago for a fair price and enjoyed the first years boating. It all started to go wrong however when the engine started to play up and was in need of too much attention. I decided to replace the engine. Whilst it was off, I thought I might as well do a little tidying up too.
This was the starting point...


With engine, a-frame, tubes and console off I turned the boat over and put it back on the bunk trailer for a few months of filling and polishing. The hull was dull and covered in old antifoul, scratches and the off minor dent in the keel.


A good clean and a lot of patient sanding, filling and polishing and it was starting to look a lot better. The keel needed a fair bit of scratch filling and was never going to look good left white as the filler and original gel were slightly different colours. To cover and protect the keel I decided to flow coat it red to match the tubes. New decals were also fitted.
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Old 11 March 2015, 18:11   #2
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Country: UK - England
Town: Whitehaven
Boat name: Pegasus
Make: Zodiac Pro 530
Length: 5m +
Engine: 115hp Merc 4st
Join Date: Oct 2012
Posts: 337
With the hull underside done I flipped the boat back over and sat it on its nice new trailer. All the rollers, fittings etc on the old were shot and the bunks had trashed the hull. I think it was also overloaded as it was un-braked so it now sits on a nice new Nicholson roller trailer.
The next job was to fix a few small hairline cracks in the transom. The gel coat was very thick in some of the corners on the transom returns and around two engine mount holes and had cracked. I ground out the gel (glass was all fine) and replaced with loads of additional CSM to stiffen things up a little more (way bigger than the original crack). I also had to widen the engine cut out as the old mariner was particularly narrow. The old a-frame holes also needed filling and re-drilling.


The console was next. The old one was sturdy but grubby and full of holes. I had always had 2 32l fuel tanks on deck in front but it used deck space and looked crap. I found this one from Ribs4u.co.uk at a very reasonable price which takes a 70l plastic fuel tank with ease.

I ordered the tank and console and set about them. First job was to cut the hatch holes. Found a very handy wire and hose running tool at home too!

I glassed in an additional shelf just above the fuel tank for the battery, in the front section, a storage box under the seat (with access space to fuel tank sender) and ply stiffeners to the insides of the front section for screwing stuff to then flow coated the lot (inside). Hatches were added along with fuel filler/vent and windscreen.
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Old 11 March 2015, 18:12   #3
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Country: UK - England
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Boat name: Pegasus
Make: Zodiac Pro 530
Length: 5m +
Engine: 115hp Merc 4st
Join Date: Oct 2012
Posts: 337
I wanted to hide the cables and wires to the engine. This meant going under the deck. There was already an old exit hole with plug near the transom but on removal just went into the hull void, which offered no protection to any under deck kit. From an old post on here I knew that there were no lateral stringers in the hull so I could run cables from console to transom. I came up with a plan and made some flanges on the lathe to fit 2Ē suction hose, allowing me to secure it at each end. 2 holes were cut in the deck where the console would be and another next to the existing one at the transom. Using rope and a lot of brute force, I dragged the suction hose through the boat and fitted the flanges. One duct was to feed the engine rigging (battery cables, control cables, fuel and 14 pin harness) and the other for lighting cables, steering lines and any other stuff.
You can see the deck flanges either side of the fuel tank under the console. The green pipe was added to prevent the ducts filling with water as they are sealed from the hull void and will not be easy to drain. No water can enter the hull though of the console floods.


This shows the tube, flange and engine hose through the splash well, before being screwed down.

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Old 11 March 2015, 18:13   #4
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Country: UK - England
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Boat name: Pegasus
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Engine: 115hp Merc 4st
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The hunt for a replacement engine didnít go well. I wanted more power and a much newer engine and reliability is a must. I looked at the few used suitable engines around and decided on a new Tohatsu or Honda 90. Just before I ordered, the new Merc range was released offering a lighter option than the Honda and more sophistication than the Tohatsu. As the Merc 115 was the same weight as the 75 and 90, I though, bugger it, the hull is rated to 120, why not!
It is BIG! It dwarfs the old 75. It is, however, only as heavy as the 75, aux 4.5 and bracket. The aux wonít fit any more so the transom load is the same.

I opted for the Smartcraft upgrade which, after some fitting queries (see my other posts) is now fully working and, although still big, looks good. It tilts with about 5mm free space under the a-frame. The gauges look great and negate the need for separate trim and fuel gauges.
The down side to smartcraft is the mass of wiring in the console. There is tonnes of it with meters of spare harness coiled up in there. Thankfully itís a big space so there is still plenty of storage in the upper and lower compartments.
With the new engine came new baystar steering. That was a doddle to fit. I also re-did the electronics with a new lowrance link 8 vhf and Garmin Echomap 50dv. Hopefully these will play nice and the AIS targets will display on the plotter. I can only check that when I get out on the sea.
I also added a compass and a nice stainless bar to stop sun glasses and other stuff falling off the top of the console. All in all Iím pleased with the look and layout.
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Old 11 March 2015, 18:19   #5
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Country: UK - England
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Engine: 115hp Merc 4st
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The final jobs have been to fit all of the various little bits like the 12v socket under the seat (to attach a battery charger or for phone/hand held vhf charging), re-welding and re-fitting the a-frame and general tidying, new light wiring, new antenna, new D-rings, new seat cushion etc. I also painted the deck and fitted a new tank rack. I plan to add a removable cushion to the rack for extra seating when out with the family. It is now pretty much finished and I think is looked quite good. Just need to finish the remaining bits and bobs and then wait for calm weather and initial sea trials.

This is how it now looks......











The next project is to fix up the dive club boat (under the cover in the background).

Phil M
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Old 11 March 2015, 18:47   #6
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Make: Ribcraft 4.8m
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Engine: Tohatsu 60hp + aux
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RIBase
Excellent job.
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Old 11 March 2015, 18:51   #7
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Thanks for posting. It all provides an incentive to push on with my own renovation.
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Old 27 March 2015, 16:44   #8
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Country: UK - England
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Maiden voyage this evening and wow! With the extra power the boat is a completely different animal. So responsive and quick yet almost silent. I am very impressed with this engine. All the other lor worked perfectly too. Radio and ais all talked to the plotter, console and seat very comfy and the launch was easy on the new trailer. Massive grin factor! Got about 52 kph at 4500rpm but was a bit too rough to push any faster. Next time I'll go with company and try to get some photos.

Phil
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Old 27 March 2015, 17:40   #9
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Sounds fab.
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Old 27 March 2015, 18:31   #10
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Enjoyable read. Looks great, good job
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