94 550 leaking oil and gas through the hull

I just picked up some skis and this 550 has a hole in the gas tank from sitting the last 4 years. Theres some gas and oil in the engine compartment and it is now soaked through the fiberglass and is leaking from the bottom of the ski. Im wanting to know what im gonna need to do to fix it or if it's worth fixing. Heres some pictures so you guys have an idea what im working with.
 

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Vumad

Super Hero, with a cape!
Location
St. Pete, FL
The fuel is going to weaken the glass. You can either run it as is or you can cut out everything involved and replace it. I can't say how safe it is to use, but it looks like a very large area is involved including the engine mounting locations. 550 are t very expensive and it'd probably be much cheaper in time and money to get a different hull than to replace all that damage. If you do decide to cut out the damage, I can tell you how excluding installing new motor mounts which I have not done. Ask before you cut it, because my way would need it intact.
 
Lol id really like to try fixing. So no setting it on fire. I do have another kawi ski but it's a like a 85 440 idk if the 94 550 motor will fit. Things look a little different.
 

Vumad

Super Hero, with a cape!
Location
St. Pete, FL
Lol id really like to try fixing. So no setting it on fire. I do have another kawi ski but it's a like a 85 440 idk if the 94 550 motor will fit. Things look a little different.

Well, the only way to fix it is going to be to cut out all of the damage and rebuild it. You could easily be 200 in materials, and if you do my on-the-part mold method then you are looking more like $300 or more in materials. It adds cost but reduces labor, significantly on something like that. Plus, you will need to rebuild the motor and other hull mounts.
 

Vumad

Super Hero, with a cape!
Location
St. Pete, FL
Its very simple, but adds extra cost. It requires that you can access both side of the project, so if the damage extends past the bulk head, it may not work for you. The reason to use this way is that it can allow you to minimize the work to recreate the proper shape, it allows a repair to be vacuum bagged saving some weight.

Wax the hull because it is your plug. in your case you are going to need to isolate the hull with visqueen, packing tape, or something else that will protect the mold from contamination

Layup glass, on your hull (aka your plug) allowing for a decent overlap of the area you are going to cut out of the hull. Allow dry, remove. This is your mold. Making the mold out of iso resin could save a little money, but the repair must be epoxy, so it may save you more to buy epoxy in a larger volume.

Cut out the damaged area and prep the hull. You will need to make sure everything that is saturated has been removed, and everything you are keep is throughly cleaned a sanded.

Wax and then Reattach your "mold". Ratchet straps would work good for you.

Layup your repair frp the inside. Start by rebuilding the thickness of the hull and complete with a significant overlap.

It would be a good idea to layup on the outside too since this is such a big job in such an important area. (Obviously after you remove the mold) (i have never tried it but ypu could potentially line your mold with a layer of glass before you reattach it, which would put a wet layer on the outside and a sandwich in the process, ive never done it, so im not sure it would work)

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Some important things of note. You need to determine how much glass you need. You can start with a thinner layer like the 1208 biax i like, and then use some thicker material like a heavy weave to build thickness quicker. The mold thickness is relative to its size (overbuioding is a waste of money while under building will cause distortion). I would suggest you speak to some who can calculate how much material you need for your given thickness to minimize costs, as you can then buy just the riht amount of glass and use that to calculate your resin needs (i keep extra material so i just eyeball it). If ita your first time, baggong the repair is probably not a good idea.

Just realize yoi are taking pn a huge project and the costs could be much more than the figure i ball parked. I think this would be a good project to salavage a superfreak, ricker, etc, but i think this job is a waste of time and money. I think you should just get a different hull. But, if you are dedicated to the learning experience, dont mind the cost and accept a high chance of failure, it would be a good learning opportunity.
 
Wow thanks for explaining all that. It seems like a lot of work but id like to see it get fixed. I know its just an old slow 550. But all the skis I have were handed down to me by my step dad. So they have some sentimental value. Because these are the skis I grew up riding. Im just worried that it is to big of a spot to be repaired and might just be forced to get a new hull. Would you possibly know of any sx hulls?
 
I vote to hang it in the corner of the garage with some ropes from the ceiling. If you were really cool you'd make a dummy and put an old "slippery when wet" wetsuit complete with gloves,helmet, goggles to make it shred frozen in time......
 

Vumad

Super Hero, with a cape!
Location
St. Pete, FL
If it's sentimental to you, I think you should either cut it in half long ways and hang it on the wall. I would even go as far as cutting out the side of the engine compartment and tray, and mounting a LED clock in the side and a shelf. Tray could work good for the clock or one shelf, and engine compartment could be good for clock and a shelf or a tall shelf or 2 shelves.

I think you could make it into a badass prop, AND buy another 550 hull, for what it would take in time and money to fix this mess.
 
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