Great Lakes Bass Fishing Forum

About Fishing Products including Make Your Own => Boats, Outboard Motors, Prop & Trailer Talk => Topic started by: Bad Poncho on October 15, 2012, 08:35:50 PM

Title: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Bad Poncho on October 15, 2012, 08:35:50 PM
Hey everybody! We are in the process of beginning a restoration on our 1990 Gemini 200DCX, my father bought the boat new in 1990 but was parked in 1995 until now.  

(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4421.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4423.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4424.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4425.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4429.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4431.jpg)

So at the end of day one we had the front deck stripped down to the old glue.

(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4457.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4460.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4461.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4463.jpg)

http://www.youtube.com/watch?v=8JRl_uCzSCg
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Bad Poncho on October 15, 2012, 08:36:58 PM
Day two progress!

Day two of the restoration we stripped the carpet from the floor and the rear deck, with the carper completely stripped from the hull it is just about time to start sanding the old glue off and think about the new carpet. I apologize for no pictures today, did the video though. Hope you enjoy!

http://www.youtube.com/watch?v=k-yVb5AzMtY

(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4512.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4513.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4517.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4522.jpg)
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Bad Poncho on October 15, 2012, 08:37:56 PM
Day three of the Project Poncho build was a day of hard labor, though you may not see it we have spent many hours scraping the aluminum lids until they became spotless, the fiberglass proved to be a different beast entirely.

When I first began scraping on the fiberglass flooring it came off extremely easily after being exposed to the open air. While the large majority of the rear deck, lids included, were incredible easy to remove the glue there was a couple of curve balls when it came to the fiberglass. It seemed as though the glue had bonded with the glass resulting in me having to sand off the excess until it became even with the fiberglass.

Tools used:

14-in-1 tool - $6

Acetone (Not needed for a majority of it but may come in handy) - $7

100grit sandpaper (Never hurts to have extra sandpaper) - $10

http://www.youtube.com/watch?v=1iu0RAXwtc8

Before
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4512.jpg)

After
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4643.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4644.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4645.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/100_4646.jpg)
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Bad Poncho on October 15, 2012, 08:38:40 PM
Day four was spent scraping the front deck, this was best done by scraping it dry with the 14-in-1 tool then following it with the acetone. The acetone works for you in two ways, it helps to soften to glue and it also cleans the fiberglass allowing you to see spots of glue that you may have missed. After I did a quick move around the deck with the scraper I then used a broom to get any of the fine debris out of the way so that I could better ensure I cleared off the loose glue fibers. The last step of the day was to use a paper towel that I put acetone on to make one final check for loose glue before calling it good for the day.

http://www.youtube.com/watch?v=V0OSz4yvcN8

(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/IMAG0002.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/IMAG0003.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/IMAG0008.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/Gemini%20Project/IMAG0009.jpg)
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Bad Poncho on October 15, 2012, 08:39:44 PM
Hey Guys and Gals!

We finally got out of our financial slump and picked up a new-old 1986 Johnson 200! The motor was cosmetically rough but the top end was rebuilt with only 5 hours on it! Check out the transformation! The hull is going off for paint over the next few days then we can keep on goin'!

(http://i110.photobucket.com/albums/n99/TransAmRocker/102_5483.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/100_5487.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/100_5494.jpg)

http://www.youtube.com/watch?v=fd-OsgmI7zI
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Bad Poncho on October 15, 2012, 08:40:21 PM


Another week and more progress on the Project Gemini build! This week we received the boat from paint, if you are looking to save yourself some money when getting your boat painted the preparation is what takes the most time for the paint, so why not do it yourself?

The first thing you will want to do is decide if you are getting new carpet or not, if you are remove the carpet, once the carpet is removed you will then move to removing the doors. The doors on the boat will be covered either by carpet or a bed liner depending on the route you wish to go so there is no need for therm to be on the boat while it is being painted. Getting paint under the hinges and in the water channels will be much easier with the doors removed as well.
Next up is the rough up the gel coat/fiberglass. You will want to start this by stripping the wax and oils from the hull, you can get stripper from most hardware stores though I personally use Dawn Dish Soap after my mother stripped through the wax AND gel coat on the Gemini years ago, but that is another story in itself. Once you hit it with the stripper you then want to follow with isopropyl alcohol to ensure all of the residues are removed from the boat, these residues may gum up your sand paper.

Once the hull is nice and clean we then used 100 grit sand paper to rough up the hull, followed by 120, then finished off with 150. Many people use 80 grit but I personally find that to be too course. Once you sand over the entire paintable surface your will then follow up with more isopropyl alcohol before applying the primer.

When painting fiberglass cars in the past we have used a product known as Feather Fill, this product is a sandable primer that will actually build up and fill some of the small imperfections in the fiberglass. I will note that on our project we did NOT use it to show what can happen if this is not done. I HIGHLY recommend the Feather Fill because it will show you in the imperfections it did not fill, those imperfections will need to be fixed with fiberglass resin.

From there is a matter of either painting the boat yourself or sending it off! These steps could save you as much as $2,000 in shop time, you will figure out why once you complete the prep work.

Before:
(http://badponchooutdoors.com/wp-content/uploads/2012/10/100_4422-300x225.jpg)

After:
(http://i110.photobucket.com/albums/n99/TransAmRocker/100_5644.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/100_5646.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/100_5647.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/100_5648.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/100_5649.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/100_5650.jpg)
(http://i110.photobucket.com/albums/n99/TransAmRocker/100_5651.jpg)
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: bsimpson on October 15, 2012, 08:43:40 PM
That is awesome!!!
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Dave B on October 15, 2012, 09:04:57 PM
Sweet looking boat!!!!
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: YpsiBass on October 17, 2012, 11:38:59 AM
It's like night and day.  Nicely done.
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Bad Poncho on October 17, 2012, 12:02:32 PM
Thanks! I still have a bunch left to do but hopefully this weekend I'll be hanging the 200 on it!

Still left:

Fiberglass Work - Fixing small pits and extending front deck
Replace Pumps - Livewell, Bilge, Custom Cooler(?)
20oz Carpet - from BassBoatSeats.com (http://BassBoatSeats.com)
Seats - from Bass BassBoatSeats.com (http://BassBoatSeats.com)
LED Lighting - BluewaterLED.com (http://BluewaterLED.com)
Custom Panels - Custom made switch/gauge panels from scratch
Mount Electronics - Minn-Kota Maxxum 70lb, Humminbird 788ci DI HD

I'm sure I've missed something but we shall see!
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Mike S. on October 17, 2012, 06:55:44 PM
This is a cool thread. Awesome project. I have never heard of one of those boats. I am anxiously awaiting pics of it totally finished. Sure beats paying for a new boat. So what's the story on the boat?  Why did it only get used for 5 years and then sit so long?
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Bad Poncho on October 17, 2012, 07:30:44 PM
Gemini Boats was owned by Billy Westmoreland, the smallmouth guru himself. The boat was designed to function on Dale Hollow, St. Clair, and Erie with ease. The "wings" on the hull allow less water to come over on to the deck which can be an issue on those bodies of water.

My father purchased the boat new in 1990 after winning the majority of tournaments in his local trail, the Barry Country Hawg Hunters, he did so out of a 14' that he and his partner converted into a bass boat with a 1956 Johnson outboard.

The Gemini was bought at Lake and Lawn in Plainwell when he went to go pick up a 18' Aluminum boat, instead he stumbled upon the 20ft Gemini with the 200 for only $16,000 and affordable payments, not to mention they gave him $400 to ensure he made the first payment. On the test drive the dealer hit 84mph and that was all-she wrote, well that and a check. That year he and his partner went on to win the third AOY in a row.

The boat features a 40 gallon livewell in the front and two 20 gallon livewells in the back, The front deck measures around 8 1/2' though with the extended deck it may be more like 9' of deck length. As I mentioned earlier the boat had a top speed of 84mph with the 200 which was a deciding factor in the boat.

I was born in 1992 which is when the boat began to sit. My father more-or-less stopped fishing for 5 years and began working 40-60 hour weeks and spending his off time with his children. When I was around 10 he rebuilt the motor and beefed it up to 260+hp which propelled the boat to over 90mph. That winter mice got to the motor and nested inside the cylinders, rending the powerblock in need of repair yet again. To make matters worse that summer my mother decided to do my father a favor and was his boat, with Dawn, evidently Dawn strips wax and gelcoat.

Here we are today, working on the rebuild for my first real bass boat, I have been fishing out of a 1993 Quantum Fish-and-Ski and I love it, which is why it will be my next project.
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: motocross269 on October 18, 2012, 08:00:41 AM
Cool boat and great pictures...

Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Mike S. on October 18, 2012, 04:11:08 PM
Sweet. 1992?  Man, I'm young, but you are really young. Are you going to do any custom graphics on the boat, or just leave it white? 
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Bad Poncho on October 18, 2012, 04:22:57 PM
It will have my logo across the side along with Humminbird, Minn-Kota, Bluewater LED, BassBoatSeats.com, and whoever else is wanting to sponsor us.
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Mike S. on December 20, 2012, 09:15:49 PM
What's up with the boat?  Is it done?  Did it get put on the back burner?
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: BadPoncho on December 20, 2012, 09:24:49 PM
Nope, we've actually been hard at work carpeting the boat, the deck lids are taking more time than expected since the shop that painted the boat got overspray all over our $25 latches.

Alkyd enamel is known for being a strong resilient paint but the paint shop we had do our work put it on WAY too thick, on day one we noticed a ton of runs and dust in the paint but that stuff can come off with a bit of light sanding. That isn't the major issue we have however, we did notice that the paint in the motorwell actually created a puddle under the paint that had gelled over, also, the boat came into contact with water for the first time today and the paint literally fell off.

It is very HIGHLY recommended that you do not cut corners and use the correct poly paint. Looks like the next move forward, or backwards rather is the try to start fresh.
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Mike S. on December 21, 2012, 03:49:04 AM
Bummer.
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: BadPoncho on December 21, 2012, 10:36:25 AM
Bummer.

Yup, we did use Visions Auto in Kalamazoo so I wouldn't recommend them. Looking like we may have to go from scratch which could help some the community though so all is not lost!
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Waterfoul on December 21, 2012, 01:57:20 PM
Bring it to Kelly at Fiberglass Products in Grandville.  He's an old timer who's forgotten more about painting and gelcoating boats than any of us could ever learn.  He's done some work for me, my friends, and several of my customers and I highly recommend him.
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Mike S. on December 21, 2012, 02:58:05 PM
Bring it to Kelly at Fiberglass Products in Grandville.  He's an old timer who's forgotten more about painting and gelcoating boats than any of us could ever learn.  He's done some work for me, my friends, and several of my customers and I highly recommend him.

Can he fix the scratches in the side of my boat? 
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Waterfoul on December 21, 2012, 03:41:01 PM
Bring it to Kelly at Fiberglass Products in Grandville.  He's an old timer who's forgotten more about painting and gelcoating boats than any of us could ever learn.  He's done some work for me, my friends, and several of my customers and I highly recommend him.

Can he fix the scratches in the side of my boat? 

Yup.
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Mike S. on December 21, 2012, 07:19:49 PM
I called them today. I just have to find a nice window , after bass season is closed, to drag the boat down to him for an estimte and possibly to get it done right away. I got an estimate from a guy here in Muskegon, but I'm not real confident in him for some reason.
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Waterfoul on December 21, 2012, 11:03:21 PM
Did you tell him I sent you?  He might charge you more if you do!  LOL!!!

Bet he tried to talk your ear off... he likes to talk.
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Mike S. on December 22, 2012, 04:42:54 AM
I will tell him who sent me when I meet him. He's a customer of yours, right? That's good husiness. And yes, he likes to talk. If he can fix my scratches, I will listen to whatever he has to say.
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Waterfoul on December 22, 2012, 08:08:23 AM
I will tell him who sent me when I meet him. He's a customer of yours, right? That's good husiness. And yes, he likes to talk. If he can fix my scratches, I will listen to whatever he has to say.

He's a "sometimes" customer of mine... buys epoxy from time to time.  He should come in more... I can save him money in the long run.  I probably send him more business than he does with me at my store, which is fine with me.  Anyway... he's a good guy and I'm sure he can fix you up.
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Bad Poncho on January 06, 2013, 06:29:35 PM
So we do have an update! The shop now all of a sudden said they will fix the paint free of charge after they received word of what the project was for. Also, removing the rub rail and over the next week or so I will be sanding her down myself to make sure things are right before it goes back to paint.

_____

Removing a rub rail on a bass boat is relevantly quick and easy, though it can quickly become a nightmare if you aren't careful and strip out a screw head or two like we did. If that happens though there is nothing like a drill and a pair of pliers to get out of a bind!

Step 1: Remove End Caps
Step 2: Remove Inserts (Rope or Rigid inset)
Step 3: Remove Screws
Step 4: Remove Rub Rail

Step 4 should come along with step 3, the rub rail should fall off as you remove the screws.

Have questions? Comment below or visit http://badponchooutdoors.com

http://youtu.be/7MCiCYYWGfY
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: BadPoncho on March 12, 2013, 12:34:05 PM
FINALLY, with the warmer temps I'm able to get back at it and making very quick progress which is very frustrating in some way. Sanded the entire top of the hull in around 4 hours by hand, the paint adheared great to most of the "wings" but the channels of the lockers had some issues with peeling.

(http://i110.photobucket.com/albums/n99/TransAmRocker/th_IMG_20130311_170218_zps1e8b50cb.jpg) (http://s110.beta.photobucket.com/user/TransAmRocker/media/IMG_20130311_170218_zps1e8b50cb.jpg.html)

Look for a few videos over the coming weeks!
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Bad Poncho on October 05, 2016, 07:02:04 PM
Hello boys and girls!

It's been quite a while since we've worked on the project but with the changes here at home we can finally get back to knocking things out day-after-day until the snow flies. Back in 2013 we had begun a project to resurrect to boat my father had purchased back in 1990 from a now-closed boat sales location.

From 1990-1999 my father had fished professionally out of the boat as his sole income, in late 1999 he had come to the decision of being with the family more often and getting a "real job." This job along with family life had taken over and the boat had been neglected. Finally in 2002 the original motor blew which resulted in a fresh rebuild along with porting, polishing, upgraded carbs, and new exhaust routing. These modifications were for naught because the rebuild took longer than expected which meant the boat would sit over the winter unused, becoming a great home for mice which found their way into the motor and eventually somehow the new block had lost compression during this time.

In 2013 we had picked up the project with zeal, after making very rapid progress we had sent the boat off for paint. Sending the boat off into someone else's hands which ended in a major relations debacle causing the project to come to a halt. Now in 2016 we have our own space again and the progress is once again very rapidly happening. Follow along while we make the magic happen!

https://youtu.be/oyav5utJUfQ
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: Bad Poncho on October 17, 2016, 06:38:19 PM
Well, I got my steering cables broken free thanks to some Hoppes 9 gun solvent and a pair of vice-grips. The biggest breakthrough was getting the cable out of the tilt-tube which had been rusted together previously. Now that the steering is known to work we can move onto removing any of the current corrosion with white vinegar from the hardware store and get moving to winterization and planning of the switch planels, gauge cluster, and other more detailed type stuff!

https://youtu.be/nLzbnwwupC8
Title: Re: Bass Boat Restoration Project - 1990 Gemini 200 DCX
Post by: djkimmel on October 18, 2016, 02:23:47 PM
Thanks for sharing.