FX1 Wide tray and reinforce

kdub133

kdub133

Ive come to the conclusion that the 12" wide stock FX1 tray wasn't cutting it after seeing my friends' rockered SN builds. While im at it i plan on doing some reinforcement to get ready for surf. Here is a list of what i have planned in the build. I have been going on it for a few weeks slowly and decided to start a thread on my progress.

-Composite Pole pad
-Wide tray similar to the blowsion one in the picture
-defoam
-fix all the wiring mainly bilge
-reinforce whole inside with extra layers in high stress areas
-dual cooling
-Surf ready hood (stock liner keeps seperating)
-probably more when i find stuff along the way :p

This pocked style is what im planning on going for
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Cut the tray open and started defoaming
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3 hours later all the foam is gone some was wet and the exhaust wont work the way it sat.
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I took out all the hoses and lines running though the hull. Yamaha got silicone happy and ozed it everywhere so i had to get it all off the hoses because some was loose and would let water through. planning on epoxying in all the tubes
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sanded the whole inside of the ski with 40 grit and got ground down all the extra glue
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installed the dual water lines and got a 2.5" tube running though the hull now. stock was 2"
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kdub133

kdub133

Decided to change gears for a night and do some glass work.
I have had some experience with composites at school on the Baja SAE team doing carbon, Kevlar, glass wet layups and vacuum bagging. But i wanted to use a piece to practice on because i know i'm not going to be vacuum bagging the whole ski and want to see how wet to make it. After dealing with composites a bunch i knew i didn't want to do carbon because the weight saving is wasted when i know i'm not getting a vacuum on it to suck out the excess resin and its already going over a resin happy build from the yamaha factory. Kevlar was also shot down because i'm not going for abrasion or puncture resistance in this case being that im mainly looking for added structural rigidity.

I really liked the look of black engine bays and didn't really want to spend 50ish dollars a yard on carbon for color, nor did i want to paint it so I decided to give black pigment for the resin a try.

I decided to lay up the pole pad first for practice because its going to be hidden anyways. Being at home and not having pva or a spary gun at the time i went through the house and found some canola oil to keep it from sticking and decide why not, it was a test piece anyways.

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I feel like it came out pretty good for laying up right over a untouched plastic piece wiped down with cooking oil.
 
kdub133

kdub133

Here is a long over due update on the build


Got the cord gripper
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Made some Rickter inspired surf fins
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Closed up the fire wall, reinforced and installed tubes
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Pink foamed the whole deck
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Threw some parts in with a powder coat run at work
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kdub133

kdub133

Glassed the whole deck and rail
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So much better than the narrow tray

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did some cleaning up of the ebox, bilge wiring, installed new connectors on msd and box, and ran wire sleeving.
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Finished all of the engine bay reinforcement, and all the glass work on the ski
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Now the start of the motor work :p
Port matched and opened up the b pipe to 47.5mm
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Should be getting the cylinder back from porting on Friday!
 
VXSXH20

VXSXH20

Sionis Industries
Location
Mid-Atlantic
Did you lower your exhaust tube below the tray deck, and thru the bulkhead now that youre running long foot pockets?
-Where does that cord gripper go? I assume that's the steering cable gong thru a stainless tube? a weather proof compression fitting over the cable?
 
kdub133

kdub133

VXSXH20 said:
Did you lower your exhaust tube below the tray deck, and thru the bulkhead now that youre running long foot pockets?
-Where does that cord gripper go? I assume that's the steering cable gong thru a stainless tube? a weather proof compression fitting over the cable?
Click to expand...

Yes I lower the exhaust tube. The steering cable is in the stock grey plastic tube that's in a slightly s shaped under the exhaust tube. The cord griped is for the trim and is in a separate plastic tube on the non exhaust side. The cord gripper is water proof.
 
VXSXH20

VXSXH20

Sionis Industries
Location
Mid-Atlantic
looks great kdub ! I sent you a pm. looking forward to seeing this done and a ride report. The power coated brackets look awesome and much more appealing than the old green stock color!
 
kdub133

kdub133

Sorry for the update delay.

Put the powder coated parts on.
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Installed the 08+ sj impeller
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Got my cylinder back from Boyko Racing. He did a killer job.
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Put motor together with new ada head.
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kdub133

kdub133

Turfed the ski with the help of a few friends.
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There is no comparison with stock. The difference is unreal, almost forgot how small they were throughout the process.
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Finished up the pole pad. I ended up liking the pillow effect the stock pad had, so i used under pad and shaved it.
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Put the motor in.
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Installed the front foot hold across the front
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kdub133

kdub133

I finally made it to the lake to break in the motor and test it all out.

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So stoked on how it all turned out but its still going to get some more things done before next trip out. The motor ripped super hard for a 61X with a stock 44 and the tray was awesome to be able to catch yourself and hold the ski stable at speed.

The final things I need to tackle should make it even better.
Bought a Versiplug.
Still need to finish and fit the lightweight hood.
Bought some Blowsion tubbie IIs from a friend and need to install them
I'm thinking about throwing some graphics on it. I really like IPD's styles but i have my own vinyl cutter and software and want to make it have a unique twist.
Further down the road I may cad design, do FEA, and build an adjustable pole to run in place of the AC racing one that is on it currently.

I am open to any ides you all may have on the graphics. Here is a basic one I threw together really quick.
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kdub133

kdub133

Here is the final outcome of the ski
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All in all the graphics took way longer than I initially anticipated and the next day i took out the remaining wrinkles and trimmed them a little better.
 
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