Shetland 535 refurb step by step

[Whammers]

In between the transom operations I also managed to fit the windscreen. This was not without its challenges!  First problem was how to hold it in place while marking and drilling the holes for the mounting screws. Luckily, there is a hole near the centre of the mounting face where cables for nav light and horn come through and I inserted a bolt through this with a 6" long piece of wood to act as a spreader/clamp. With this contrivance, I clamped the windscreen centre in place and then it was easy to mark the holes one by one. After marking, I removed the screen and drilled through with a 5mm drill bit. This made them tight enough for the M5 machine screws to tap lightly into the GRP, which enabled them to hold the screen in place while I nipped inside and fitted the nuts and washers. I did them one at a time so that the screen was finally secured bit by bit.

The screen came with horrible carriage bolts but I've discarded them in favour of A4 stainless steel pan head screws. Each screw has a rubber washer and an A4 stainless steel penny washer on each side to clamp the screen up nice and snug. The outermost screws have larger blue anodised washers, just for a bit of extra pizazz.

I'm quite happy with the finished article, though I'm not convinced it would be strong enough to mount poppers for a canopy..

Meggy 103 Windscreen fitted.jpg

Meggy 104 Windscreen fitted.jpg

[Whammers]

The past week has been characterised by agonising over the proposed orange on the hull, researching alternative ideas and arranging to get the engine put on an engine hoist so I can clean and paint it.

During my research I discovered Rustoleum Hard Hat aerosols, available in a huge range of RAL colours, and a device for attaching to an aerosol can to give a better spray pattern for large areas. Could this be the answer to the patchy finish? We shall soon find out as I've ordered some white aluminium spray paint and a trigger spray device. I will now roller the bottom of the hull in blue and do a sprayed topcoat of silver on the sides.

I wasn't able to get to grips with the engine as it's not yet on the hoist but I did remove the top cover and begin its refurbishment. The 20-odd year old Johnson decals were laboriously removed with a heat gun and scraper and the whole thing rubbed down ready for paint. The cover will be done blue and the lower sections of the motor silver. I am also going to rebadge the engine as an Evinrude. They are the same engine anyway and I just prefer the Evinrude name.

[Whammers]

The refurb of the motor cover is now complete. It was a satisfying job. I decided not to try and replicate the factory look but went entirely my own way, matching the colour scheme to the boat.

The cover was looking very tatty before I started and needed dismantling and completely rubbing back to the gel coat. I then primed it and finished off with Rustoleum Hard Hat spray paint in ultramarine blue.

The end covers were old and brittle and broke when trying to remove them so they were replaced with new ones, made from leftover black perspex I had in the garage.

Meggy 105 Motor cover before.jpg

Meggy 108 End covers.jpg

[Whammers]

Meggy 106 Motor cover mid.jpg

I also removed the air intake cover and painted it in satin black, then finished the job off with some chrome and red letters, bought from ebay for 69p each.

I'm quite pleased with the finished job. Now I just have to make the rest of the motor live up to it!

Meggy 107 Motor cover done.jpg

[Whammers]

Next job was fitting the transom pad. I put a thick bead of Sikaflex 295 around the inner edge, about 1cm in to minimise spew when the panel was screwed in place, then offered up the panel to the transom. Holding it un place while lining up the screws with their existing holes was not easy but I managed eventually.

The final step will be to drill through, seal and install inserts in the motor mounting holes and the splashwell drain holes.

Meggy 110 Transom pad.jpg

[Whammers]

One of the things that will be needed eventually is a 5/6hp auxiliary motor. I'd been keeping a casual eye open for one and spotted a classic Evinrude Fisherman 6 on eBay. It was in my home town, which seemed too good an opportunity to miss. I went for a look and ended up bringing it home in the back of my camper van for £70..

Meggy 111 Aux outboard.jpg

So that's another refurbishment job I've given myself. .

Since we now have two Evinrude engines my wife Gill has christened them Big Ermentrude and Little Ermentrude (Ermentrude = Evinrude) or Big E and Little E for short. ..

[Whammers]

Little E needed a head repair (stripped spark plug hole) and a repair to the broken gear lever. I've now fitted a new thermostat and a brand new cylinder head (which was a bargain - new old stock at £15. The gasket cost more!) and a new pair of NGK spark plugs. I have yet to fix the gear lever and can't run the engine until it's on the boat and has fuel connected and is in water. Before that happens I have also to recommission Big E...

[Deleted User 5743]

Looking good, if a little upside down in some of the pics!

[CaptainPhaff]

Whammers, re running little E - have you thought about building a little wooden frame to hang the engine on so that it can be held in a dustbin of water. That way you can do all the work to get it running from the comfort of land. Nothing worse than putting the boat in the water and then not being able to use it because the engine won't run. Your refurb is coming along great by the way, it's been fascinating to follow.

[Whammers]

Many thanks chaps.

Yes Captain P I may well think about that. I just need to find a suitable stand and a dustbin or barrel of some kind..