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Replacing Engine Bay Soundproofing AR 230 06

Geoff Cooper

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Were're just coming to the end of the rainy season here in Thailand and this year apart from a few days it's been quite good and mainly rained at night not restricting boating however the last 3 days have been overcast and rainy so rather than get moody i decided to replace the Engine bay soundproofing as it was showing signs of wear and not looking it's best, I realized it was going to get messy so to eliminate as much mess as possible here's how i went about the job, I welcome any suggestions and other ideas that you may have as i had not done this before although i had had some experience with contact adhesive and the idea was to keep thing's as neat and tidy as possible, Ok here we go. Oh excuse the head gear it was 90% humidity and i needed something to stop the sweat running in my eyes as it was damn hot working there.

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I removed the top end of the hatch dampers so they just lay down out of the way and also easier to reconnect as your not bent over in the Engine bay trying to work in an awkward position.
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I wanted to tackle the job without completely removing the Engine cover but still allowing me plenty of room to work,Firstly i considered how to support the Engine cover and found this idea although gave me good access looked like it was going to damage the mating on the walk through part of the swim platform and also wasn't as secure as i would have liked so i finally decided to make a slip knot in a piece of cord and completely loop it over the lock on the Engine cover and attach the other end to the wake tower, This was ideal and allowed good space to work, You will see what i mean later.

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The next stage was to create a good working environment so a quick trip to the local TV shop for a reinforced cardboard box that TVs come in they are very strong, I managed to get one a perfect size to fit over the Airboxes and to butt up neatly to the rear of the Engine bay but you can always cut them down to size if need be, Ok the next step was to use the palm of my hand and hitting the cardboard to secure it over the Engine removal loops, It was now secure and not moving anywhere.

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Place a pair of steps on it and make sure that the feet are wide enough to sit on the Airboxes and your ready to start, You can see how neat it will fit you use the whole box just collapse it you could also use a piece of plywood if you wanted to and cut some slots in it, Oh make sure all your plugs are in the floor of the Engine bay so as no rubbish gets down the holes.
IMG_1815.JPG Ok you can see what the old foam was like it was now time to take some rough measurements and off to the Trim shop to get all the gear.
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This Guy supplies most of the local Trimmers so he knew what i wanted Fire retardant soundproofing and 2
tins of contact adhesive.
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This was before i started stripping it but i took measurements and cut the new Soundproofing so i could see the original shapes.

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Nothing was glued as yet just a good fit and holding itself in position, make sure you work the foam right into the small nooks and crannies so as to make a good job, After i had cut all the shapes it was time to start cleaning all surfaces
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Ok time to start stripping all shapes have been cut and new foam is ready to be installed.

IMG_1823.JPG The vacuum worked overtime but made life a bit easier, Look just above the 2 nuts and washers and you will see 12 small screw points coming through the Fibreglass take care they will cut you very easy as there hidden under the old foam.

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I knew it was going to get messy, I had considered laying the new soundproofing on top of the old but changed my mind as i didn't think the job would have been good enough and it would have played on my mind that i could have done better so although it was hot and messy i had a good position to work and had no need to rush.

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Wire brush the whole area then vac

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Ok when you have removed all the old Soundproofing clean all the surfaces with a rag and some thinners then Vac again, You don't want any dust on the surfaces your going to be working on, You can see those small screw ends better in this Photo.
IMG_1833.JPG I just painted a strip across the bottom of the part i wanted to stick and on the lid also just to line thing's up nicely, Don't rush you have plenty of time to work, I placed a piece of hard cardboard over my knees just to make it easier to put glue onto the foam make sure you spread it well it doesn't have to be thick at all as your putting glue on both surfaces, You can see the cord i attached to the locking mechanism and the wake tower now.
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Ok Start laying it.
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You can see how it supports itself as i can carry on applying the glue make sure you get the edges covered

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I work from the bottom up it makes life a little easier as it supports itself

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This is a bit tricky as it has to fold under and into a small shelf right at the back but make sure you get glue into the shelf and it will hold very easy but take care and make sure you get it right first time as it will be awkward to remove for a second attempt, You will see what i mean when you measure the piece to be fitted try to fit it first without the glue so you can see what has to be done.

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Ok it's all taking shape now and time to start trimming, Foam blunts knives very quickly so make sure you have some spare blades as you want to cut neatly not tare, You can follow the original glue lines around if you want to but i had an idea that i wanted to try, I only left about half an inch gap at the sides as i wanted a tight fit when the lid closed and it worked really well, You can always trim back to the old lines if you feel the need

IMG_1875.JPG You have room to work very easy without removing the Engine cover completely.

IMG_1873.JPG IMG_1882.JPG
This is the part where that shelf is i spoke about before as you can see i spent some time and made a nice tight fit, Still go lots of trimming to do so take your time, I found trimming some areas at an angle handy so the 2 edges joined together neatly, just work your way around.

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Just lay back and enjoy the job

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Spend a bit of time trimming nice and neat and then to check and clean the Engine bay itself,
Reconnect the dampers and check it all fits good.

IMG_1902.JPG IMG_1884.JPG Come on you didn't really expect me to climb inside the Engine bay did you.

IMG_1904.JPG IMG_1903.JPG
Ok all nice and clean and make sure you vac it all out we don't want any old foam getting anywhere it shouldn't

Ok it took me about a day including a very good clean up after, You can remove the rear seats if you want to but it's not really necessary, I did but only to give them a real good clean behind where you cant get to under normal circumstances, I also ran water through after i had finished just to make sure that there was no unwanted foam anywhere.

If I've missed anything just ask and i will do my best to answer any queries, It made a hell of a difference when i started the Engines up it's really very quiet now and i found trimming closer to the edge a real advantage as when you close the hatch now you just get a gentle thud, Total cost about $60 and taking her for a meal at the Seafood restaurant for cleaning the engine bay for me.

A word of warning expect some Fibreglass splinters so a pair of tweezers a magnifying glass and some TCP may be needed as it's not a job that gloves can be used, I'm sure your good Lady will enjoy inflicting some pain during the evening while removing the splinters, Take care when working under and around that shelf, I mentioned there are small rear seat securing screws protruding through the Fibreglass and they will cut your fingers i have shown them in the Photos but just in case you missed them be warned , Just take your time it's well worth it. Good Luck.
 

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Ronnie

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@Geoff Cooper , another great write-up. Thanks for taking the time to create and post it. I forgot how different the 230 cover is compared to the 240s cover. The 230 cover has a lot more surface area and curves whereas the 240s is basically four flat surfaces.

When you say it took about a day do you mean about 8 hours from start to finish?

What are the specs on the foam you used? For instance how thick or how much thicker is it than the stock material?

Now that you have done it once would you do anything differently, like using a spray on adhesive or peel and stick material?

One thing that made doing the 240 cover a little less time consuming for me was to use the stock material as a template, mine came off without tearing and I was able to glue it to the new material for added sound absorption / deadening.
 

Geoff Cooper

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@Geoff Cooper , another great write-up. Thanks for taking the time to create and post it. I forgot how different the 230 cover is compared to the 240s cover. The 230 cover has a lot more surface area and curves whereas the 240s is basically four flat surfaces.

When you say it took about a day do you mean about 8 hours from start to finish?

What are the specs on the foam you used? For instance how thick or how much thicker is it than the stock material?

Now that you have done it once would you do anything differently, like using a spray on adhesive or peel and stick material?

One thing that made doing the 240 cover a little less time consuming for me was to use the stock material as a template, mine came off without tearing and I was able to glue it to the new material for added sound absorption / deadening.
Hi i started it about midday and worked until about 5 pm and then went back the next morning about 10 am having already cut all the patterns out the previous day and finished about 2 pm in the afternoon, That didn't include going to get the materials though.
It's about a little over an inch thicker than what was on before and i was offered 2 different grades and i went for the thicker more expensive version egg box design.

I have used spray on adhesive before and not had a great deal of satisfaction with it i prefer to use the straight forward canned variety, I had no spillage or sticky fingers as i have used contact adhesive before but not on such a large scale but found the job interesting and enjoyable to do, I can't think of anything i would change because everything went smoothly with no hick ups and i had already had a good idea of tools and materials that i needed to use and had them all ready at hand because the last thing i wanted to do was keep climbing in and out of the boat that's when problems can occur. thanks for the reply.
 
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Scottintexas

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Geoff Cooper

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Hi i started it about midday and worked until about 5 pm and then went back the next morning about 10 am having already cut all the patterns out the previous day and finished about 2 pm in the afternoon, That didn't include going to get the materials though.
It's about a little over an inch thicker than what was on before and i was offered 2 different grades and i went for the thicker more expensive version egg box design.

I have used spray on adhesive before and not had a great deal of satisfaction with it i prefer to use the straight forward canned variety, I had no spillage or sticky fingers as i have used contact adhesive before but not on such a large scale but found the job interesting and enjoyable to do, I can't think of anything i would change because everything went smoothly with no hick ups and i had already had a good idea of tools and materials that i needed to use and had them all ready at hand because the last thing i wanted to do was keep climbing in and out of the boat that's when problems can occur. thanks for the reply.
thanks @Geoff Cooper great job,
@Julian can you add this to the FAQ list
Thanks for that
 

Gym

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Thanks for sharing @Geoff Cooper. I still have my engine compartment to do so this helps immensely.
 

Julian

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GTBRMC

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Great write up, Geoff! Thanks for sharing it.

You are really doing some terrific work & your creative problem solving absent dealer support, etc. that most of us enjoy in North America is impressive.

Cheers!
 

BravoMike

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Very nice write up @Geoff Cooper I know this is in my future. Will make the job easier having this as a reference.
 

Geoff Cooper

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Thanks for all the replies and compliments i appreciate your comments, Without boring you to tears i will tell you a little story, I did my engineering apprenticeship in the late 60s and was always taught to be proud of your work and if parts weren't available adapt and overcome was the motto, I worked for a company that made very big compressors for among other places the car industry these had to be able to run 24 hours a day 7 days a week, They didn't have Big End and main bearings shells they were white metal that had to be scraped and using engineers blue paste to make a good fit so you could see where the high spots were on the crankshaft and big end bearings and keep scraping them which would take me maybe 3 days to get them perfect before my manager would accept them.

About 2 years ago i had a Phone call while i was back in England visiting my family it was from an old work colleague of mine who i hadn't seen for a while, He asked me if i remembered a company i would make service calls to for the purpose of servicing there compressors i said yes why?, He went on to inform me that he was called to go there and make a service call and on his arrival he inspected the compressors that he was asked to service and one of them had my documents attached to it, On further inspection the oil was like treacle and had hardly any in the machine at all, He then noted that it had been built by me and the last time it had been serviced was by me in 1976, It had been running 24 hours a day 7 days a week since then some 36 years without a service, I asked him what he did to it he replied changed the oil and filter and the Air filters as the compression was very good and it didn't need anything else that was a compliment in itself, Thailand is like England 50 years ago they still repair things and i love to take thing's to pieces and see how they work and improve them if i can, I love going around the back streets of Bangkok to see them making head gaskets by hand in some of the small shops there and making bearings by hand also it just brings back memories of how i was taught, We don't really have dealer back up here as for the Yamaha Outboards you can get everything but for the Jet boats they stock nothing they will order for you from Singapore but you have to pay for the postage also and as they are not Yamaha themselves they charge double for anything and if you inform them that the Yamaha price is so much they reply by saying oh this is Asia we charge what we want, I find many things that can be cross referenced as Yamaha don't make all the components that go onto our Boats and they will use what they have available that will do the job so i regard it as a challenge, I hope i haven't bored you to tears but I'm one of the old school that doesn't think the word BOAT stands for bring over another thousand, Good Luck you can wake up now.
 
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Geoff Cooper

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Very nice write up @Geoff Cooper I know this is in my future. Will make the job easier having this as a reference.
I'm pleased to be of some help to you, Don't be scared of having a go just take your time and prepare thing's first it's not difficult if you think about what you need and get everything at hand first you will enjoy doing it, If you get stuck and need some advice give me a shout, Good Luck.
 

MikeyL

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GREAT write-up ~!
Best Wishes, Mikey Lulejian - Lake Oconee, GA
 

Geoff Cooper

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Great write up, Geoff! Thanks for sharing it.

You are really doing some terrific work & your creative problem solving absent dealer support, etc. that most of us enjoy in North America is impressive.

Cheers!
Thanks for your kind words, I have replied to you and the other people that have written to me with a short story of what happened to me a couple of years ago, I never walk around with my eyes closed and am always looking for tips and ideas and only to pleased to pass them on, Where all in the same Boat for want of a better word, Take care and good luck.
 

msavold

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@Geoff Cooper: looks good - better than the factory job!
Did you by any chance measure dB before and after? This would have to be an improvement over stock.
 

Geoff Cooper

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Great write up, Geoff! Thanks for sharing it.

You are really doing some terrific work & your creative problem solving absent dealer support, etc. that most of us enjoy in North America is impressive.

Cheers!
@Geoff Cooper: looks good - better than the factory job!
Did you by any chance measure dB before and after? This would have to be an improvement over stock.
I have no means of measuring the db unfortunately, This is Thailand and we have only just got electric Ha Ha, What i can tell you is it's about 50% quieter then before and I'm well pleased with the result it was worth doing, Thanks for the reply and Good Luck.
 

Geoff Cooper

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Ok i have been cruising the Islands all weekend and i can honestly say that the Soundproofing was amazing, Cruising about 7500 rpm i could hardly hear the engines and it was a massive difference compared to the original Soundproofing that was on there before, I'm well pleased and would certainly recommend doing the job to your boat it's at least 50% quieter.
 

rkluck

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Wow that is great! I was going to add something else but maybe I will change my mind. Sounds like the new 2015 sound deadening.
 
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