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I've had the exact problem posted above happen to me, fuel line is collapsing on the inside. Most fuel lines are double walled and can look fine on the outside, while the inner liner is getting soft & sucked on hard enough by the fuel pump it's collapsing. Also not sure if you mentioned it but...

Interlux makes a nice epoxy barrier coat, not too pricey. They've also got a big selection of bottom paints depending on your needs. Whatever you decide to use I'd recommend sticking with the same brand when it comes to the barrier coat/bottom paint.

did you squeeze the fuel primer ball until it was filled before trying to start?

bring a regular backup filter with you, I've had the O Ring serving the petcock valve blow out on those clear plastic bowls. Once they do that they suck air & you'll never get a prime.

if you've got a big oil filter sized fuel filter be sure to bring a wrench to take it off. And a backup filter. And some rags to clean up the mess. If your filter has the plastic bowl with a drain cock be ready for that to crack an o ring suck air and fail. Make sure all your fuel hoses & oil...

Fixing the wood rot in the fwd compartment could get into a whole lotta mess once you tear into that. The hull is foam filled outside those walls, and I believe theres another full height stringer between those walls and the side of the hull. Any way to see if the foam is wet? Drill some...

ACR PLB+, floats & has a light, plus a Cobra MH600 handheld VHF that has GPS and DSC feature, floats, water or manually activated light, bluetooth so you can use it to make calls thru your cell phone, lithium battery that seems to last forever plus an AA battery tray.

The boat looks great, if it's reliable & if you don't need the extra cockpit space right now I'd hold off on making any changes. Sounds like you've already done quite a bit of hardcore maintenance stuff, I'd enjoy it for a while. Closing in the transom + bracket is a lot of work and $$$. How do...

nice boat, I've got a 1990 same model. Did you relocate your tank to the front area? If so does it ride any different than when it was in the back?

check the website of the local big box stores too, a lot of times they'll sell items like that online only but have free shipping to their store for pickup. Not sure where you're located but in Palm Beach County theres a place Sunray Plastics that has all kinds of sizes in stock.

The difference between the two models should just be the piston diameter & possibly allowable travel stroke. The two models 'might' use the same outer housing if theres an inner sleeve that makes up the piston bore, where two different sleeves could be used with the same housing, but I doubt it...

Bar Keepers Friend works great too, also sold at Home Depot & grocery stores. If its got oxalic acid in it, it'll work on the rust stains. Also keeps the ants away.

Pacer makes some nice stuff too. https://www.pacergroup.net/electrical-parts/breaker-accessories/

could be a blocked check valve at the tank/fuel pickup tube.

don't know about original replacement parts - but a few things to replace if they're looking old is the 40A main breaker switch mounted on the transom/in the bilge, its usually on the starboard side if you've got a factory bracket boat. Blue Sea makes a nice replacement. Make sure your seacocks...

thats pretty much what I want to do. was there enough space between the top of fuel tank & bottom of deck to run the fill hose? or did you leave the plumbing on top of the deck?

I think your Explorer well is a little wider than mine, 24" long x 9" wide x 18" deep, 15 gal, I could go a little deeper but theres just not enough room for decent sized baits to turn around. Will probably end up putting a round 25gal on the deck just in front of the transom well, can hopefully...

I've got an Offshore 24 with full transom/factory bracket, anybody replace the transom livewell with something bigger or add another on the deck? I use the livewell under the helm seat for other things & it's too shallow for what I need anyway, the rear transom livewell is just too small. Was...

I've got the same boat but w/the single bracket, 1997 OMC 225, 15x17 prop, tired bottom paint but no growth, my numbers are 4000, 23 4200, 25 4500, 29 5200, 33 don't remember what I got a wot but it would reach 5600, this old engine is gettin tired.

definitely put a cover on the battery, I'd be a little nervous if I had to change the filter offshore over the battery. ps - I found your 3/16 drill bit.