Shetland 535 rebuild.

[redex]

Before rebuild, actually worse than it looks..JPG

Five years in !!! spare time project.
Retired, moved and now live in a cabin on Brightlingsea Creek, Essex. Built a dock in the first year, so had to get a boat !!!
My first (and only) boat restoration. I have never owned a boat before but have been around them.
Only got the cabin and door left to do !!!.
1972 Shetland 535 bare hull rebuild, all holes filled and damaged repaired. There were 127 holes through the fibre glass when everything was removed. 1983 Mariner 60 (Yamaha 60C rebadged) rebuilt. Cost over £1,000 in bits (£400 for the CDI alone). Did the work myself. Power head off to access gear selector. One in 3 bolts sheared so have become a dab hand at threading and helicoils. Cross hatching still visible on bore, all seemed original so no need to strip the block or head. Compression 145 psi and 143 psi. Old motor with very low hours, transmission was also oil tight with no signs of wear. Carbs rebuilt, vacuum balanced, idle mixture and timing adjusted. All service items replaced and new coils, fuel pump, thermostat, water pump and gear selector fitted. Achieved 29mph (SatNav) before running out of revs (prop too small and wrong pitch, now fitted something a bit more leisurely). Did get out of the hole very quickly !!!
Everything replaced except the rev counter and log. Modified motor well drains to empty all debris and water. Cabling tidied in an umbilical. Hatch fitted. Floor sub-frame created. Hull gel coat retained, top deck re-painted. Twin bilge pumps, twin 120 amp/hr leisure batteries. Added a volt meter, temperature gauge and remote choke switch. Fitted tinted screens and got a cover made.
Any ideas on the cabin door, I fancy a barn type door, possibly modify the existing item ?
Mariner say 50:1 petrol/oil, Yamaha say 100:1, so running 75:1 with good quality oil as I will very rarely be running above half throttle, have to spend first 30 minutes of any trip at just above tick over due to speed limit.
Regards Neil

[redex]

I have posted 2 videos of the outboard after re-building it. First dry run, and first sea run (fitted to the Shetland 535)..
https://youtu.be/2j4oBbr-5m0
https://youtu.be/sUzvMdnL1Rw
Regards Neil

[Carey]

That looks really nice

[DaveClark]

Love the boat mate
Lovely colour blue
I’ve just brought a 535 and loving putting my personal touches to it
I’ve only had it 3 weeks, and not been in the water.
I’ll send pics
Just tested the 5hp engine only for the Thames so for now that will do.
Just updated seating in cabin.
Be interested to see how your cabin is for ideas.

[DaveClark]

New impeller, tested my 5hp outboard
Runs lovely

[redex]

Hi Dave,
nice boat, how old ? serial number ? Thought about window conversion like you have but decided to retain the original shape. Yes they still leak, nothing a bit of sealer won't fix !!
Sorry, not done a single thing in the cabin yet other than repair fibre glass damaged. It is a blank canvas !!! I found a few useful bits on a VW Transporter caravan site !! Small sink, cooker, storage, lighting etc. Maybe get some ideas from there. There are also several good 535 upgrades if you search the site and the net.
Send me a photo of the registration plate of your outboard (on the bracket shown in one of the photos you sent), I have a data base that may shed some light on it, manual etc !! Need to be able to see all of the numbers, if not just write them down.

Regards Neil

[DaveClark]

Hi Neil

Thanks, I’ll send the plate over asap for model number etc of boat and outboard
I never fitted the windows but wish in a way that they were actually original windows as they would look more original
I’m nearly ready for the 1st launch, just brought a remote throttle kit but still need to buy the cables
It looks easy to fit the steering and gears to outboard but not sure about the tiller cable conversion, could be just a basic clamp ?
But not sure
After that’s fitted I’m ready.

[DaveClark]

Throttle kit I have brought
I just need the 2 x cables for this if you know what ones I should buy
Like I said really not sure about connecting onto the throttle on outboard

[redex]

Hi Dave,
you will need a kit to convert from tiller/throttle to remote tiller and throttle. Anything is possible but this is likely to be difficult and expensive. Depends if the outboard is Mariner or re-badged Yamaha. If the serial number plate says made in Japan it is a Yamaha and will also show a model number.
I would suggest you look at buying an outboard already set up for remote control. Then sell yours.
Regards Neil

You are going to need something like this :

https://www.perfprotech.com/mercury-mar ... ?model=469

[redex]

Hi Dave,
an alternative is a tiller extension. This will give throttle control and a small measure of steering control. No gear shifts. At least you will be able to stand and see where you are going. I use one in my dinghy so I can sit forward to keep the boat level.

https://www.force4.co.uk/item/Force-4/T ... -140cm/E5X

Regards Neil