Custom/Hybrid Footrocket - First build (rebuild)

[hurcorh]

Hey guys. Bought a footrocket a few months back. Working away from home though makes it hard to find time to get things done on it though.

When I purchased the ski it had a stock engine / pump setup with a Coffman exhaust.
At first I had planned to just pop a Jetmaniac Top end kit on it and B pipe but like a lot of projects i'm sure most people could relate to, things started escalating.

A quick thanks to Chris from Jetmaniac, Watty from RP crew, AJSP, Cold Fusion and anyone else who's helped me along the way with answering questions and their suggestions.

Parts list that I've ended up with broken down by supplier or brand
Jetmaniac:
720cc ported top end kit / pistons, new bearings / rings / gaskets etc.
JM Factory B pipe Head pipe SS bolts
Ratchet hood strap kit
V force 2 reeds

Thrust:
Black Carbon inlay girdled head (From RP crew)
Black pissers and Black Bildge outlets
Ezy pull trim (already had reduction nozzle and steering nozzle). Did not know it had a trim nozzle when I bought it and did not plan on running a trim system but seeing as half of it was in place, I figured what the hell I might like it.

Cold Fusion:
Fuel filters
Black fuel tank (Second hand)
Coupler Kit
Flywheel holder tool

701 Industries:
Engine Mounts
Battery tray
Fuel tank and battery straps
Trim 'Duro' Nozzle.
New Hood seal

Pump:
Driveshaft was perfect so i'm using it but got an 11/17 prop, solas 12 vane and SS wear ring plus new bearings / seals from Rp Crew

Carbs:
Rebuilt stock 38's with genuine Mikuni parts, added bulb type primer kit.
Freeriderz Inc dual 38's airbox adapter plate
Painting the carburetors and intake manifold with Dupli-Color
Added a fuel selector as I like having reserve fuel

Freeride Innovations:
FRI fuel selector knob
FRI carb covers and throttle drum
FRI Bilge switch knob


Exhaust:
Brand new B pipe (couldn't find a second hand one) from AJSP
Krash Industries Waterbox
Jet works flow control valve for stinger
Added second water cooling fitting to the exhaust manifold. My first time drilling / tapping threads went very well.


Steering / Controls:
ATP finger throttle
ODI lock on grips
ATP steering / pole (already installed when I bought it)
Turfed my Chinpad as the ATP one is quite bland I thought and had some surface paint cranks.
Also turfed the outside of my footholds to add a bit of softness to them.

Electrical:
Dual rule bilges
MSD enhancer and boot terminal kit
Three way bilge switch mounted in dash.
All other electrics stock.

Jeeze when I break it all down, it's quite a list....

First pics are of how I purchased the ski. More pics to follow in the next post.

 

[hurcorh]

Turfed my chinpad and top of the footholds. First time using hydro turf I think it went well. I used duct tape after turfing the footholds overnight to ensure the edges were well stuck down. Still contemplating whether or not i'll turf the rails. Mostly for aesthetics and to prevent any further damage as they rails have some splintering and small cracks. Opinions?

 

[hurcorh]

Installed new MSD boots and connectors on my spark leads. Installed MSD enhancer. At first I had two white wires crossed and was only getting spark when I would initially hit my start button and when I would let off of it.

I did not know the Factory B pipe exhaust manifold came with a single cooling fitting I just assumed it came with two so I had to tap a second onto it. My first time tapping threads and it went surprisingly well. It was harder than expected to find NPT taps or fittings where I live so I used BSP instead and some thread sealer. I was very happy with how it went. I also had to grind down an old spanner to use to tighten the two inner bolts on the exhaust manifold. A poor design flaw I think.

 

[hurcorh]

Painted my intake and Carburetors. Not really necessary but paint was falling off of my carbs and I had spare time to kill one day. Cleaned the carbs with carb cleaner and the paint just fell off with a light brush from a toothbrush. Easy as. Removed choke plates and installed primer spigots etc and fully rebuilt carburetors with supplied spring and jets from JM with his recommendations. Also installed T handle low and high adjusters.

Installed the Cold Fusion Coupler on my midshaft and engine. Jetmaniac Midshaft holder tool made it easy with a long pry bar for the midshaft and the Cold fusion flyhweel on the engine made that side easy. Changed my crank seals before installing the new coupler too.

Can't install my midshaft back on yet as I'm waiting for my Solas 12 vane, wear ring and prop to arrive so I can do proper alignment before installing the midshaft. That'll have to wait till Dec 29th as that is when i'm home.

 

[hurcorh]

It was my first time rebuilding a two stroke engine. Was good fun! I used the great wonders of the internet including this forum for everything from torque specs, case seal installation and 'how to assemble a 701 engine' from the tech help FAQ section.

The next few photos are of the stock head when I had removed it along with the top of the old pistons. From what i understand, from these photos it is possible to deduce the engine may have been running too lean? I don't have photos of the spark plugs I removed. But the carburetors had not had the brass 'anti tamper' plugs taken out so the high and low adjusters were not changed and the jets were stock size. I am thinking that due to running the coffman exhaust without making changes to the carburetors this possibly leaned the engine out? Opinions would be appreciated.

Last picture is of the engine after reassembly with new crank seals, Jetmaniac Top end kit and gaskets etc. Installation and re-assembly went smoothly with the help from Chris from Jetmaniac, his notes that came with the top end kit along with, again, the help of others and this forum's search function.

I didn't paint the bottom end of the engine. To be honest, couldn't be bothered I was just itching to get it back together. Would have painting it black but not a massive deal really.

 

[hurcorh]

No more photos for now as i'm away at work but i've also installed my waterbox, battery box, mocked up fuel tank and fuel lines.

Installed trim lever and cable (the thrust cable is so long!) along with their replacement steering cable fitting.
Also installed the trim nozzle on the reduction nozzle ready for when my solas gear arrives to assemble.
Made up wiring for twin bilge and installed bilge's into ski (either side of midshaft). Also drilled the holes for the two bilge outlets.
Set my B pipe adjuster screws after first removing them and installing anti seize.
I sealed and screwed the stock krash scupper closed. I leave my ski floating next to the jetty overnight when in use so didn't want to risk water slowly leaking into my hull if there overnight and I didn't want to run a bilge all night because of this.
Installed 701 Industries engine mounts
Purchased a Deka battery

Best thing about this build I would have to say aside from learning heaps would have to be all the stickers and free T shirts! Now where to put them all......

 

[hurcorh]

Update. Ski is pretty well done. Everything is together. A tight fit! Got to do some carby tuning when I get her on the water. Registered it yesterday ($355 for a year in SA)

Got the Solas 12 vane and 11/17 prop assembled with new wear ring, thrust trim and 701 ind trim nozzle. Looks awesome.

I had initially planned on running 701 engine mounts but in the krash hull it sat my engine too high in comparison to the midshaft as i hadn't told Dave I was using a krash hull when I purchased them. 2 or 3 mm so i have to use OEM for now.


Leak down tested the engine before installing it. Had it running on water for a few minutes, checking for leaks, setting idle, etc. Compression read 170 psi (35cc domes) and that is with a cheap comp. gauge I will probably buy a good quality one soon. I've also got a deka battery to replace that motobatt just using that for all this initial stuff

 

[hurcorh]

Took the idea off of another member on here for a jetski cover. I cut it out and had my handy mum on the sewing machine to do the hard parts. It just has a piece of elastic running through it. Turned out really well.




Also turfed the rails. Went easier than I expected. I used baking paper to keep the turf from sticking so I could properly align it piece by piece.

 

[makejetskiinggreatagain]

Nice footrocket! the turf on the rails came out really nice. your mom did a great job on the cover as well!