97 SJ Build

[marz831]

I am moving this here from my blog because it just doesn't seem like many people really look there. The conversation is usually good for an idea or two.

Here is how it sits right now:

The paint on the ski is in great shape. The top deck will stay red. I will repaint the hull either white or black after I glass in the tubbies and fix the back corner. It will need to be refoamed also as it is very waterlogged. I have no idea how long the damage was at the back of the hull before I noticed it and it was literally making a puddle of the garage floor from dripping.

Here's a set of x cases that I am going to use to build the motor. They're pretty nasty as this was the motor from a square I had a few years ago that had a nasty water ingestion incident. I will be picking up some mildly ported x cylinders this week so I can start to get the motor together. I'm basically just putting off the glass work because I hate doing it.

 

[marz831]

Finished up some disassembly tonight. One of the heads on a pump bolt is stripped and three of the heads on the intake grate bolts are stripped out. I started to drill them out, but I figured that since I'm cutting the tray out anyway, I'll just punch out the pump insert from the inside. I figure I will just replace the pump shoe rather than trying to fix the intake grate inserts. What a pain in the ass. Anyway, next step is to deturf and defoam, probably the worst part of this whole process...

 

[marz831]

Got all of the turf off the tray.

Cut my first piece out of the tray and holy crap! The foam was wet up to about a 1/3 of the way up the gunwhale. You can see the waterline on the left in this pic.

Started digging some of the foam out and found where one of the leaks was coming from. This tube was just loose in the bulkhead. There was no sealant left. This was probably the wettest part so far.

 

[marz831]

Cut out the footholds and the rear portion of the tray; got some of the foam out.

Turns out that it wasn't the head of the bolt on my pump that was stripped. The insert was actually spinning. Going to 5200 all four of them because it seems like the hull was leaking there also.

 

[marz831]

Got almost all of the foam out tonight. Going to try to finish defoaming and pull out the exhaust tube tomorrow. I would leave it in except I need to fix the corner of the hull from the inside and the tube is in the way.

 

[Mike W]

Man that looks like alot of work. I dont envy you a bit. Good luck.

 

[Geeshow]

marz you can find aluminum or stainless steel tubes at ace hardware. it comes in two to three foot, and also 1/4 3/16 3/8. i used the 3/8 for water lines and trim tube.

 

[tom21]

way to go!!! I also don't trust the 5200 foothld install, figure a leak there. just my .02

prybar works awesome for defoaming as does a nice serated saw or tree pruning blade. I wonder if a pressure washer would just blast that schitt out of there? messy but fun and quick. be a pioneer and let us know how it works.

 

[marz831]

way to go!!! I also don't trust the 5200 foothld install, figure a leak there. just my .02

I'm not sure what was used to install the holds. They were in the ski when I bought it. Def not epoxy + filler though.

prybar works awesome for defoaming as does a nice serated saw or tree pruning blade. I wonder if a pressure washer would just blast that schitt out of there? messy but fun and quick. be a pioneer and let us know how it works.

Most of the foam is out. I might go down to the self serve car wash to blast the rest of it out.........I'll wait till dark though

 

[marz831]

Did a little bit of work to the ski over the past few days, not too much though. I decided that I am going a different route with the tray/footholds so I cut some more of the tray out. Resealed the pump inserts with 5200. Glassed over the hole in the back of the ski from the inside. Also glassed over the rear exhaust outlet. The rear exhaust is staying but I want to do something a little different with the outlet.

 

[Moto360]

marz,
Ever think of a side rear exhaust? That way tail stands would be easier. The pump would not fill with exhaust. I saw it somewere but can't remember were.

moto360
2000 Superjet
1989 650sx
1988 650sx

 

[JetSkiDood]

Nice job so far......Here is the thread with the rear side exhaust, looks really sweet....

http://www.x-h2o.com/threads/21724

 

[Crab]

Seems like Caker has that side rear outlett.

 

[marz831]

Nice job so far......Here is the thread with the rear side exhaust, looks really sweet....

http://www.x-h2o.com/threads/21724

Yeah, I was considering that. We'll see.

 

[Moto360]

Thank you jetskidood. That is what I was talking about.

Moto360

 

[marz831]

Didn't get to do very much today. I thought I had enough glass to do the reinforcement on one side, but I didn't. Just filled in the bond line with foam.

 

[Crab]

I find its easier to get "unmotivated".

 

[marz831]

I find its easier to get "unmotivated".

That's another problem. There's plenty of other things I could have done, but I just decided that no glass was a good excuse to stop.

 

[Crab]

Tomorrow I may foam in the hull and set the footholds, motivation pending.

 

[marz831]

Installed tube for trim cable. I don't plan on doing a trim system, but I figured I may as well put the tube in there while I have it apart just in case I change my mind.

Sealed up some of the stuff in the tray.

Mocked up a new exhaust flange. I am going to put an identical outlet on the other side for the one-way.