FX-1 Chadetroit's FX1 760 Build

[chadetroit]

Hmmmm I can see a Freak or BOB coming in about that?! Well keep us posted sounds exciting. While I love learning stuff while fabbing this FX1 I'd give it all up for a completely dialed in new hull that I drop an engine into, that is for sure.

 

[swapmeet]

I spent a lot of time body working my tubbies... it was the worst part.
I don't think the rear chop will take very long in comparison.

I can't comment on the effect but from everything i've been told and read, it should be noticeable.

 

[chadetroit]

chop chop

I guess I have committed, or should be committed not sure which.

also a little peek at the driveline

 

[swapmeet]

Nice!!!! Do good!

 

[chadetroit]

Thanks, that should about do it for the demolition of the hull (so no more suggestions :banghead, now I gotta get busy on the body build up.

Hey any opinions on how much of the bond line I can trim off in the rear while keeping structural integrity?.....Edited. Found some nice threads on cutting that backrail, looks like just a little more trimming then I can put the cutting wheel away

 

[chadetroit]

more body work

Got a little more body work done on Saturday.

Trimmed a bit off the back bond rail
Trimmed down the sides both in height and in length
Installed Left Tubby
Reinforced the handlepole area
Ran Aluminum rod stiffener under the hood lip (still needs glass)
Started building up the rear again from where I shortened the hull so far 2 layers of 1708 biax on each side
Chamfered the 2 cut off rear sections and epoxied them back into place
Applied some more filler to handlepole cover area

It's feeling good to be putting things back together rather than doing so much destruction.

 

[chadetroit]

all work and no play

Been buried at work lately so progress has been anemic.

Decided to put in another line for the trim system instead of using the gravity bilge tube. For this I picked up some pvc fittings from home depot and epoxied them together. I cut a through hole in a 1/2" pipe cap and picked up a black rubber stopper and drilled a hole in that as well. The trim line will run through the stopper and cap. The stopper will be placed into the 1/2" fitting and capped by the 1/2" cap thus compressing it into the hole slightly and hopefully sealing out the water.

Fitted the exhaust back in and used some sealed stainless pop rivets from McMastercarr. Put some 5200 around the flange and rivets as well for an extra measure of dryness.

Bought some polystyrene sheets at Home Depot as well and began cutting and filling the bottom of the tray with the closed cell foam. After cutting a few strips and wedging them in I found I was still getting a lot of little white foam balls breaking off form the sheets where I cut. I found that if I headed the edges up with the heat gun this slightly melted and sealed the foam so it was less prone to flake off. Note wear a mask and work in a well ventilated area when doing this step as I'm sure the fumes are a bit toxic.

 

[chadetroit]

Building up the tray

After the polystyrene was wedged in as well as I could get it I began the 4lb, 2 part foam application from US Composites. I gotta say this stuff is pretty cool. Messy as heck but great stuff.

Did the first layer just enough to get a surface I could piece the bottom of the tray back together. I shaved it flat at that point and lined up my old inner side pieces with the footholds installed. After a little dry fitting with the handlepole I stood in the tray to make sure the placement was good. It actually felt a little awkward with the shortened handlepole and the footholds because both are a departure from what I am use to riding. So I had to look at pictures of pro's and their stances for some re-assurance. Footholds are as far forward as I could make them without rerouting the exhaust. I only had to dent it slightly. I also angled the back of the footholds to the outside to give a little more room in the tray and to avoid having my feet toed way out when in the footholds.

More foam was added, shaved and glassed over the seams with 1708 and a follow up layer of some light 6oz tape.

The rears and top then needed to be shaved and glassed over as well. All with 1708 biax. I still need to follow up with some light weight fiberglass to help with the sealing and help blend the thickness of the 1708 where it meets up with the old shell.

All in all it is turning out pretty good for my first time at it. I see a bit more glass, sand, filler, sand, sand, sand, sand in my future. Warm weather is here so I gotta hurry.

 

[gto0209]

I got itchy just looking at the pics.

 

[chadetroit]

Yup been scratching for days and I think I'm overdue for a new shop vac filter.

 

[chadetroit]

put it on the scale today just for a reference. It is at 97lbs hull only without turf.

 

[swapmeet]

Great progress, I weighed mine before I sent it off to be painted and it was 110 with turf and underpad. My painter claims he sanded 10lbs of filler off the ski before he painted it, but I haven't weighed it since I got it home.

Keep it up!

 

[chadetroit]

Swap where are the new painted pics?

 

[swapmeet]

I'm keeping them top secret. :sneaky:

 

[cole99709]

Great work, im doing a pump swap in mine, what were the measurements for cutting the tray out. I guess ill shorten my ski too. LOL Also how do i align the driveline for the 144 pump?

 

[chadetroit]

I can check on measurement for cutting the tray but you can basically see where to cut if you look at the pump tunnel and cut just to the outside of that and you stop just before the the back of where your bottom hull stops. The sides are up to you if you are going to replace the entire sides and refoam or just leave them in. A drill, a cup wire wheel with extension bar + a vacuum are your best friends for getting the foam out.

For the pump I cheated and bought a hull that already had the pump shoe and 144 pump set up. There are a couple of good threads here though if you search under 144 pump conversion in the FX1 thread. All the answers are here you just have to dig a little so move forward with confidence and start cutting!

 

[chadetroit]

Finally applying some primer.

 

[eddie0899]

what color are you gonna paint it? ski looks awsome!

 

[chadetroit]

Thanks Eddie at this point I'd paint it puke yellow if it gets me out on the water, I'm dying to ride. But alas It is just going back to white then I'll figure out graphically how to treat it with some vinyl. Block sand this weekend then base and clear early next week. Then have to figure out how all the stuff lying on the garage floor goes back in.

 

[tom21]

how do i align the driveline for the 144 pump?

you need to make a jig if you plan to cut out the glass and install a new pump area. otherwise the pump is modded to fit the hull, you align as you normally would.