Few updates. The ski is bonded! So that feels nice. As always, that is a terrifying, nerve racking process. Big thanks to Nick
@DrGonzo for getting the ski together.
Ran into a bit of a snare with how much stress was going to be locked into this thing if I didn't do some modification. I cut and fixed the tray, and cut out a hole through which the top of the pump tunnel somewhat sticks through in the tray. This will be the lowest tray a Circus ski has seen, and probably only a handful of locked in stress between the halves instead of 10s or 100s. Not a needed step, but I wanted to do it right.
Clamped it down to force the tray up, then locked it in with g/flex to seal, and carbon tape for strength.
5200 at the interface of the exhaust and firewall
This ski is going to be out on Lake Michigan more than anywhere else, so I want the thing to float in the event of some crap going down where I'm taking on a lot of water.
Aluminum pre-drilled for riveting to 6 months from now when the new HIN assignment comes in and I get some HIN plates.
On to the bond. I completely forgot to pick-up some cinder blocks to press the tray down during the bond, so I had to find a few other paper-weights laying around. Again, big toss out to Nick for helping me here - the dude's awesome. My fiancee I don't think could handle another one of these 'bonding-sessions', and she was pissed enough that I didn't come to be till 3AM after this was all done.
Next morning the epoxy for fully set. I turned up the heat in my garage to about 90-95 to speed up the cure after we got it clamped.
Laid some carbon tape between the halves both inside the tray and in the engine compartment for strength.
Leak test was successful in finding a few leaks. Patched everything with either epoxy or 5200.
Resin of course oozes out between the halves, so it goes from this
To this, after some grinding.
Next steps are foot holds, expanding urethane foam behind the holds, pump ring and intake install, then prep for paint.