300/440/550 '78 440/650 Build

[N2 H2O]

I've decided to remodel my 550/650 conversion ski. I bought it last spring and have done a lot of work to it over the past year. I've had a lot of fun riding it and am really happy with how it runs. here's the old thread: http://www.x-h2o.com/threads/97970-My-redone-550-650 I snapped the nose off my original hull, so I will be reinforcing this one heavily. I plan to do some occasional surf riding with it. I will be mainly focusing on hull mods as I feel I have the motor and pump set up pretty well for my needs. I have a 1978 JS440 hull that I will be using. The engine bay needs to be painted and the outside of the hull is already sanded down. There is no damage to the hull and it is already set up for dual cooling. This is my first time doing major fiberglass work, so I'm sure I will need some help along the way. I have bought a mint 08 rn sj handlepole, pole pad, XMV bracket, and MSD ECWI. I will get some pics up later. Here are my plans for the hull:
Widen the tray
True the hull
Fill in the fuel fill
Completely reinforce he hull
Convert to RN SJ Pole
Relocate the exhaust outlet(haven't decided on rear or front right yet)
Modify hood(move air intake and make handholds)
Paint
Watercraft Factory Sponsons(depending on budget)

Current Motor Setup:
Kawasaki 650
Milled stock head
Small pin 750 Cases
Red Top Sbn46
Bored and Timeserted Westcoast Exhaust Manifold
650 Factory Pipe
Prok F/A
Lightened 650 stock flywheel
Mariner waterbox
650 Stator and 550 ebox w/ 650 voltage regulator
Jetworks Flow Control Valve

 

[N2 H2O]

pics of the hull and motor...

 

[OldSkoot]

'scribed ! this'll b interesting for sure. I'd say go with rear EX.

 

[STOOPIDSKI]

sounds like a sweet project. looking forward to see the progress.

 

[_evan]

Its yellow inside...you sure it isnt a 76?

 

[N2 H2O]

'scribed ! this'll b interesting for sure. I'd say go with rear EX.

I'm thinking about setting it up for front and rear exhaust. My neighbor has it on his rn and it's really nice.


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[N2 H2O]

Its yellow inside...you sure it isnt a 76?

I'll check again when I get home. You're probably right.


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[OldSkoot]

if ya do a rear, please post pics and what you used for materials. ive been considering doing a rear ex. on one of my hulls ( tired of inhaling non 927 fumes when I'm stuck in the no wake zones).

 

[N2 H2O]

I'll make sure to post a lot of picture and document everything I do throughout the entire build. I checked the hull and it very clearly states that it is a 78. The guy I bought it from had a paint booth and painted one of the other skis I bought, so he might have painted the inside of this one and never got around to the outside.

 

[Austin]

Sounds like a sweet build. I have been watching for a 440/550 for the last 6 months and havn't found one for the right price. But When I do find one I will be doing the same thing as you with all my old x2 running gear.

Post a ton a pictures!! Sounds like a very sweet project

 

[N2 H2O]

I'm sure one will pop up eventually. I've found a few with mods in the last 6 months for less than $250.

 

[Austin]

Yeah in the past 6 months all there has been is 2 non running piece of crap 440's for $850 and basicaly all I need is a hull! Hopefully one will come across!

 

[Snivilous]

Yeah in the past 6 months all there has been is 2 non running piece of crap 440's for $850 and basicaly all I need is a hull! Hopefully one will come across!

Yea, people around here have no idea what a ski goes for. It's either uber crazy cheap or uber crazy expensive.

Neat build!

 

[dbattersby20]

interested to see the hull mods. i might be doing a js300 this summer with a lot of hull mods

 

[N2 H2O]

Sj pole, pad and XMV bracket came in today. I layed it on the hull to see how it fits and it's decent. I will need to widen the hood channel a little bit and sink the bracket down into the nose a good bit so the pole will lay more flat with the hull. I don't want it to look like the fx1 pole setup, which is what it kind of looks like right now. I want it to lay down in the hood channel and the bracket to be sunk down and almost flush with the hull. It'll take a lot of work on the nose, but I think I can make it work and look good.

 

[Austin]

what is the weight difference between the stock pole and the sj pole?

 

[N2 H2O]

what is the weight difference between the stock pole and the sj pole?

I haven't weighed them yet. I plan to tomorrow night. The sj pole feels a little heavier.


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[_evan]

Nice. I like that pole on there. Ill be following your build very closely since I plan on getting a hull to mod soon. Im excited to see how the tubbies will fit on there.

 

[N2 H2O]

I just got done weighing some stuff. The bare hull is 75.5 pounds. The stock 550 handlepole weighs 12 pounds with the stock subplate and pole pad. The rn pole weighs 8 pounds with the pole pad.


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[N2 H2O]

I got some Fiberglassing materials today, so i started cutting. I have a waterlogged hull that I will be practicing everything on before I do this hull. I made a mold for the pole bracket area with cardboard. I cut out the nose area on the spare hull and taped in the mold. I think it turned out pretty well. It will be way easier to reinforce the nose with it cut open. Next up is the hood...