cracks, leaks, foam, and old bad work.

starcrafttom

Active member
So where do I start. My boat is 3 years old but has a lot of mileage and hours on her and those that know me know that I use it a lot and use it hard. I like to cruise and fish for hours. I have run to P.L. inlet from the San Juan’s in one day. We have slept in the snow in the San Juan’s three times. What I am trying to say is that I use my boat. But I have been having problems that I wanted to get fixed but just could not stop using the boat long enough to do it. Well the weather sucks and I am taking classes for my dive cert for the next few weeks so I thought now would be the time to get it fixed. The problems are many and should not be problems on a three year boat so I called the factory to see where they want me to take it. My dealer is Les and he is not a dealer anymore and he never did glass work anyway. Wish he did but his shop just does not have the room for it. C-dory no longer does repair work anymore so I was told to take it to Sea Ray marine in Seattle.

Now I was worried about taking my baby to some go fast, wine sipping cruising boat shop. I should not have worried. I started by calling the Seattle office and telling them what needed to be done (which I will get to in a minute). Now I was ready to tell the same story to several people over and over again as I got handed down the line to the right guy, as happens in most places I have done business with. I was told to bring it down for a look and they would take care of it and let me know what needed to be done after the repair shop looked at it. Ok that sounds like a week but you have to start the process some time right? Well I towed down to Seattle and spent 45 min’s going the last 3 mile’s, the whole time looking across the lake at the Sea ray show from the truck. When I got there I was directed to the service department were I gave my name and they pulled out a work order with all my concerns type out all ready. :shock: .Ok they listened the first time, that’s nice. I was told to sign and that the fife service guys would get a hold of me after they looked at it. Fifi??? Yes they towed it to fife for me to save me gas: shock: I walked outside to drop the trailer and they had already done it for me and all I had to do was drive off. So far so good. The next morning I get a call from the service guy, Aaron with a report of the problems with my boat that I had listed and the other problems with my boat that they had found for me. They had a plan already to address all the problems and they wanted to check out a few other things to insure there were no other problems with the hull. :wink: I was surprised and please with the service that I was receiving from a repair shop for the second time in my life. The other being Les when I took my engines there for service. Now all that had to be done was for Sea ray to call C-dory to clear all work.

C-dory wanted to see the boat and go over it. So sea ray towed it over there for me the next day and dealt with the factory for me. Now I can’t say anything bad about the factory except that two of the problems I was having have been worked on before by the factory two years ago and had came back. I have also had a hard time getting some one on the phone there. I have caught them on the phone but never had them call me back but once. They have always been nice and addressed my problems, concerns and questions when I have talked to them. So The factor approved all the work that I and Sea ray wanted done under warranty :wink . So now it was a matter of when. I was thinking that is going to be a matter of weeks before they could fit me into their schedule. Searay said they could start on Monday :shock: Then I get a phone call that the factory, that no longer does repair work, is going to do the work themselves???? I guess that they did not like the price tag of Sea rays repair shop. :cry So now the factory is doing all the repair work and frank, the warranty guy, is doing it himself. I have been told that as long as frank is doing the work that I have nothing to worry about. I just don’t want the same repairs to have to be done in another two years.

So what is being done you might ask? I have been having a mystery leak in the v-berth for over a year but could never find the source. I have also had water under the v-berth at the oddest times. Now the first year we got the boat we had a leak in the bow guard that collected water under the v-berth and the factory fixed it. The weird thing is that the water only collects now when on the trailer when it rains. So I have water coming in some place that I could not find. Last week I found rain water coming in from a pin hole in the side of the boat. Its leaking is from the rub rail and running between the glass and the paint inside the cab and then comes out a hole in the paint. Sea ray found 7 loose rivets in the rail that are the heart of the problem. They also found leaks in the anchor locker. All the foam in the v-berth is soaked thru and thru with water. There are cracks in the corners of the v-berth cut out where the port a potty sits, top and bottom. So all of this is a concern and needs to be fixed by the factory. After talking to (forgot his name :crook ) at the boat show about his boat coming apart I had great concern about the hull and the core. Well Sea ray suggested that we take a core sample to see if there was any water. They had already re-cored a c-dory that had the core rot and soak with water last year. So first they did a water meter reading to the hull but could not get a good reading so we did the core sample. It came back clear and now I don’t have to worry about it anymore which is a load off my mind. Other problems are a crack in the rail near the cabin. I had this fixed before by the factory and it has come back worse now. Sea ray believes that it came back because it was not fixed right and I am of the same mind. It was fixed on the cheap the last time. I also had the fuel tank stays replaced after they pulled out the first year. The factory replaced them with glassed in wood strips. These are now falling and are being redone again. I am told they will be done the right way. There are a lot of fair sized cracks in the transom and motor well that need to be repaired before they become bigger. I also have a lot or cracks in the cabin wall on the driver’s side that needs to be repaired. Now the factory is going to take care of all this under warranty and they will pull the foam out of the v-berth. To do this they have to cut holes in the v-berth so I am getting three hatches like the new boats for free.

So all in all I am impressed with Sea ray and Aaron and his crew. They were quick, polite, informative and to the point. They communicated well with calls and email with photos of the boat and transported it for me. I wonder if the factory will tow it back for me or not?? The factory has been quick to make the decision to fix my problems and did not argue about anything that needs to be fixed just who was going to do it. Now the factory has a lot of different people working there then the last time they worked on my boat so I hope that it get’s fixed right and I have been told that frank knows his glass work and is the guy to do it. We will see how it all turns out soon. The bad part of all this is that I wanted to fish a local derby next week but now have no boat :cry so who want to take me fishing ????? Tim???
 
Wow Tom, quite a story. It looks like Lake Union SeaRay and C-Dory are stepping up to the plate. That's a step in the positive direction and is good information in case we have a warranty issue. I don't wish to start anymore "C-Dory quality issues" nonsense but I'm a little concerned because we have a 2005 CD22 as well and I've noticed water in the cabin from time to time. Dave S has been telling me to check the v-berth inspection hatch to see if it's wet. I'll do that this weekend.

BTW, what day is the fishing derby next weekend?

Peter
 
Tom,

I'm glad that you had a good experience with Lake Union Sea Ray (LUSR). I bought my boat from them and I have nothing but good things to say about them. I know some people had some issues with them working on Honda motors (they are a Mercury shop), which I can't speak to, but all my dealings with them have been very professional.

Best of luck with your boat!
 
Tom,
I hope they get the leaks and stress cracks corrected for you.
I know I had a heck of a time with the stressing and flexing of my hull.
Looks like you and I both will be "boat ho's" for a while.
I hope to be back on the water by the end of April.
 
Thanks for sharing. Perhaps there are fewer new orders, and the factory crew can do it for less labor cost, than paying LUSR.

I agree that the problems should have never happened in the first place, or that they should have been fixed correctly the first time. I wonder if there needs to be some glass, re-enforcing rather than just gel coat repair where the stress cracks are forming? (Remember in my 25, there was just one layer of glass, and lots of filler, so we had to put in a lot of glass--and there were more than "stress cracks")
 
Glad their covering it under warranty. I think its from all the times youve run around heading out of Everett. :roll: Or maybe it has something to do with how you load the boat on the trailer, I think you violated the no wake zone last time I saw you loading your boat on the trailer. :wink:
Cheers,
Tom
 
I hate to see everyone running to the factory every time they spot a stress crack.... yes, if you have serious problems... but our boats will develop stress cracks just from the way we use them.... rough water causes pounding and pounding causes flexing and flexing causes stress cracks.... not the factorys fault... some if it is ours....
I have cracks where my deck house meets the hull in the back....just like everyone else... and a few well earned ones in a few other spots....

I am amazed at the things the factory fixes... I doubt you would find very many other boat builders that do so well with warrantee claims.

I was hurt once on the job.... and suffered permanent hearing loss because of it...diden't want money...just the noise to go away... Boy did they fight me... and I just finally gave up and just decided to live with it...and that was my employer !

Joel
SEA3PO
 
joel, I say stress crack in a nice way. some are bigger then others and some are deeper then others and some leak water. the ones that where fixed before where not done right and thats why they are back. I an glad and impressed that the factory is not argueing with me about it And will get it fixed quickly. Service has not been a problem for me with the factory. Some other things they have done in general has but that is more of me not agreeing some of their decisions. The water coming in from where ever it is come in at is a problem that does need to be taken care of and NOT BY ME. Wish I could work on boat for a living but I dont. I sell house's to people. So I need work done by others.
 
SEA3PO":nvyxbj94 said:
I hate to see everyone running to the factory every time they spot a stress crack.... yes, if you have serious problems... but our boats will develop stress cracks just from the way we use them.... rough water causes pounding and pounding causes flexing and flexing causes stress cracks.... not the factorys fault... some if it is ours....
I have cracks where my deck house meets the hull in the back....just like everyone else... and a few well earned ones in a few other spots....

Joel
SEA3PO

Joel I will respectfully disagree with you on this one. A properly built boat will not develop stress cracks. You should fall over in the cabin before your $80,000 boat starts to develop cracks from use. I mean unless you are carrying 3000 lbs of gear or something.

The 2002 - 2005 boats appear to have the worst track record from what I recall reading on this site but it's great that the factory is taking ownership of these problems when they occur.

As long as major problems are more the exception than the rule, and as long as they honor the warranty, they will be a good boat manufacturer in my eyes. No manufacturers are perfect and it's impossible to buy a boat at any cost without some level of QC issues.
 
This is a scary thread for a guy like me to read, considering switching to a C-Dory from my no-nonsense aluminum hull. I know you all love to bash Bayliners, but in the early 1970s, we had one. It was 16 ft. long with a 120 hp i/o and, as a teenager, I LIVED to abuse that boat. It was all about sharp, hard turns at WOT (I called them "torque turns") and trying to throw my buddy/passengers sideways from seat to seat. I lived to get that sucker airborne and succeeded on the large cruiser wake many times on Lake Washington. No cracks ever developed in that hull, never had any outdrive problems for the first twenty years, minimal motor maintainence too.

Though I drive more conservatively now, a boat that needs to be treated gently is as interesting to me as a rifle that groups bullets at 3+ inches at 100 yds. or a handgun that does the same at 25. No matter how pretty it might be, I'm not interested when there are so many others that can far outperform that with rugged simplicity and reliability. CW
 
GLASSPLY
This was the boat of choice around here in the late 70's
I had a couple of them. very heavy deep v boats.
very good boats too.
 
Yep... I too have had boats that I rode hard n put away wet... but none of them was anything like the C-Dory... I lusted for a Boston Whaler... finally bought one...and hated it... totally a miserable wet boat in the ocean fog... cold one minute, cooking yer brains the next... super lake boat... but not for me. The C-Dory is perfect... stress cracks n all I would not hesitate to buy another..

Joel
SEA3PO
 
I just sold my old boat and have been wanting a c-dory for quite a few years now... Is it just me or have I been reading about more and more quality probs with the c-dory lately??? :sad
 
maxone2003":hz1kij6x said:
Is it just me or have I been reading about more and more quality probs with the c-dory lately??? :sad
The key is "reading about........."
When I was in epidemiology we used to say if you just look at the numbers there's no HIV in Africa, or China, or India, or Russia! For my money it's more important to have good surveillance and accurate reporting, whatever the area of concern. Just my opinion.
 
"Stress cracks"; often this is refered to an area, where there is excess gel coat, and at an inner radius. This type of "stress crack" is not structural. The CD 25 I purchased had structural cracks--that is cracks which went below the gelcoat, were several inches long, and related to lack of fiberglass backing.

My Tom Cat is also developing more cracks at the cockput combing/aft cabin house intersection. This is an area which may have excess gel coat, or it may not have enough glass. It is an area, where there may be some hull flexiing. I am watching these cracks--and as they develope, will probably grind them out (V with a Dremel tool) and see if there is lack of glass, or too much gelcoat. I am also going to watch these areas as we go across waves.

I have owned boats which had the "stress" cracks--which were not structural. That is not a worry. If the cracks are structural--then it is a problem.
 
c-dory has growing pains like every one else but seem to taking care of it. My cracks in the rail are common for c-dorys of that year. C-dory has fixed all the one's brought back for repair. I have not heard of any of the newer boats having crack so that tells me that c-dory has fixed a design or building flaw, and thats what a good company does. Now I have to admit that I USE my boat alittle so I expect a few problems now and then and I expect it to get fixed under warranty. Thats why they give you one. Its not like Iam spenting $10k on a starcraft. I spent $54k on a fully loaded 22ft boat. So yes I expect stuff to get fixed. So far the service that I have recieved for the factory and both dealer that I have dealt with has been great. So dont think this is me bit@hing about c-dory. Its not the problems that make a company its the way they handle them.
 
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