Surfriding Freestyle Surf B1 build

[KTM434]

Well I've been waiting to do this build for a long time but have been extremely busy for the last year selling my house in NH, moving to FL and being stuck in motels for 3 months with no garage or access to my toys. I have just over a week to get this build done for Wavedaze so I may not be the best at posting pics and progress as I go. I will do my best but I'm having computer/phone issues with photo bucket.
I mostly ride surf because flatwater bores me and I cant afford a flatwater freestyle setup. The ski is a fun setup the way it is already but Im looking for more so I am chopping 3.5" off the back of the hull and cutting the nose off and reshaping it with more rocker.

Current setup includes:
62t/61x 84mm 760 big bore ported by RIVA
Riva girdled head
RIVA intake manifold with reed spacer
Dual 44mm carbs
Factory mod pipe
RIVA rear exhaust
UMI steering
WORX scoop grate
Stock rideplate
Solas 15.5/18.5 impeller
Dakine X-lace footstraps
Pitbike bars


Mods will include:
Lower custom shaved seat
Blowsion trim
-3.5" cut off the back
Rockered nose
Rear mounted waterbox (waiting on parts)
Solas mag pump (on waiting list)
Hooker 10/16 (will do 11/17 if needed)

 

[KTM434]

pulled the motor out and sold the jettrim seat and RIVA waterbox:

 

[KTM434]

Marked lines 3.5" inward to cut off. If you look closely at the top deck there is a rectangle section of fiberglass that is cracked. Looks like that section was cut out previously (probably to install the Riva rear exhaust even though it doesnt need to be cut for that install):

 

[ChadGnarly]

links dont work jamie

 

[Freakrider]

links dont work jamie

same here..says Invalid Attachment specified.

 

[KTM434]

Should be fixed now! Im trying to post my progress from this week so far just to get everyone up to date on this build.

Cut my 3.5" off the back and foamed it for laying glass. Was going to use the pink foam insulation board for houses but didnt realize being in FL that they would only have 3/4" thick sheets since they have no winter here. I didnt have much time to waste and didnt want to pour foam in the back since its hard to access and doesnt have much shape to it. I found sheets of styrofoam which I wasnt too excited about since its hard to shape it but I needed to get the job done. Here are pics of the foam and then the first 2 layers of biax on the outside. Im going to do 1 more layer of biax on the outside and then 2-3 layers inside:

 

[zimmy]

Looks good Jamie, hurry up now!

 

[KTM434]

Marked out the lines on the nose somewhat freehand with minor measurements from the tow loop for symetricy. Cut it out with a sawzall then taped cardboard inside and stood it up and poured 3 layers of 2-part flotation foam. Thats where Im at right now so far. I have a lot of sanding and shaping to do to the nose. I cut that cracked rectangle section out of the top deck in the back and removed the foam to lay glass on the inside too.



Heres the sections that have been cut out of the hull:

 

[KTM434]

Looks good Jamie, hurry up now!

Thanks Craig! I know Im VERY limited on time and it doesnt help just moving into my house about 2 weeks ago and my wife is all about home improvements and getting everything setup the way she likes it. Shes just gonna have to sit back and wait for now

 

[zimmy]

Thanks Craig! I know Im VERY limited on time and it doesnt help just moving into my house about 2 weeks ago and my wife is all about home improvements and getting everything setup the way she likes it. Shes just gonna have to sit back and wait for now

I hear you man, there are a few times a year I have to ask the wife to do the same, preping for a freeride is serious business!

It looks like you are heading in the right direction with what you are doing, you will have thing ready in no time!

 

[ChadGnarly]

should be pretty sweet, wish i could do my rockered nose blaster this year but thats for next winter

 

[KTM434]

Well I used up all my foam last night and this is the final result. Everytime I got done shaping it and stood back to look at it I wasnt happy so I kept adding foam to blend further back on the hull. There is a concave section in the hull (similar to the Gen1 X2 that people do the bottom fill mod to but not nearly as deep) that makes it difficult to continue the lines further up on the hull to the nose... You can see the sections Im talking about where Im pointing. The final result still doesnt have perfectly flowing lines but its about as good as itll get unless I foam back toward the intake grate. I am pretty happy but I may cut back on the top deck and bring the rockered face higher up on the hull in front. Let me know what you guys think. I still dont know if Im 100% satisfied. If I shorten the top deck in front closer to the gas cap that will raise the rocker which I will probably do tonight before laying glass. The other thing I am unsure of is how skinny the nose is. Id like to widen it but its tough with the amount of taper it has from the factory. I plan on running tubbies at some point so I may do it then. The skinnier rockered nose is more similar to a Q8 and may be better for keeping spray out of my face but I just want it to be wide enough to do its job.


after adding more foam further back and blending the lines:

 

[ChadGnarly]

Looks good i would just cut more off of the bond line.

 

[KTM434]

Yeah the bond line is getting cut back when I'm done... I wanted to shape the foam and create the new shape before cutting too far on the bondline. You can always cut more but you cant un-cut it if you think you went too far. I'm probably going to keep the bondline close to the nose like a Rickter. Even though the nose will be somewhat skinny I think it'll be good combined with Tubbies. It'll Hopefully have all the benefits of a rockered nose and still keep spray out of my face. The Tubbies will help with flotation to help keep the front end up but I'm sure the -3.5" chop and rocker will do just fine without Tubbies. That would be a mod for down the road.

 

[KTM434]

While my hull was upside down the hood seal started to become unglued. The seal is in good condition and isnt pinched but I ordered a surf seal from Stunts318 on this forum last night and he shipped it out this morning. I also just got a Jetnetics flywheel in the mail and ordered an MSD enhancer to go with it.



I had electrical issues last season with CDIs and start/stop switch so I had Twinturbostang redo all my wiring Rad Dudes style. Heres the before and after pics:

Before: After:

 

[KTM434]

I didnt end up adding any foam but I cut further up/back into the top deck on the nose to raise the rocker higher. I layed 3 layers of 17oz biax and alternated the directions of the weave on each layer. I didnt take any pics while laying each layer of glass but I took pics of the final result. If you look closely you may see the 3 layers overlapping eachother (on the last pic you can see 2 of the layers on the side and also see the 3rd layer was brought pretty far back on the hull). I feathered each layer further back on the hull to blend it in to the existing hull smoothly. Looking at the side view of the hull after the glass has been laid it still doesnt look exactly like what I was looking for (its a little steeper in front than I planned on) but its not your typical flat front rockered nose. I continued all the chines into the very front of the hull. Im thinking this will help for handling but still have the benefits of a rockered nose. Im excited to try it out... if it doesnt work like Im hoping then I will just tear into it again but Im thinking I will like it... if you look down at the hull you can see what Im talking about. Feedback is appreciated.

 

[Twinturbostang]

Looks great man!!

 

[KTM434]

No real visual updates to show but layed a lot more glass this weekend and bought more supplies. I removed all the foam (you can see through the glass with my drop light in there. There was a big step from the glass I laid up to the original inner hull near the motor mounts. I spread some fiberglass body filler on the seam to give the 2 layers a better bond than the foam would do. Then I laid glass over that. Its coming along pretty decently and making decent progress but its gonna be a REAL tight deadline to have this thing done for Wavedaze! (fingers crossed)

 

[zimmy]

Status?

 

[KTM434]

It's not looking good. My (empty) hull is upside down right now. I'm chopping he rideplate then I need to install the exhaust outlet and versiplugs, rear waterbox and hoses, glass in the top deck access hole and assemble everything. Spraying gelcoat really screwed me and held me up WAAY too much!! (what a nightmare). I'm working on it now but I lost my carpool buddy and I've already had 1 all-nighter this week so it may be a tough drive if it's done tonight or tomorrow morning. I'm guessing I won't be there this time but I'm gonna keep working...