Custom/Hybrid Jloria's "Ah, freakout!" build...2012 Superfreak -4.3

[jloria]

Technically started last weekend but ran into some pump install issues. I got a little bit of traction this weekend. I will be taking my time so it may be a slow build since I will not be working on it during the week.

forgive the typos upfront...i swear I can spell

2012 Superfreak Badass...Glass version...Carbon fiber hood, SF frontfoothold, carbon fiber rideplate

I will be doing a mix of flat water and surf. I wanted an all around ski and I was hooked on the SF after riding Jetmaniacs. Aerials are the bomb.

Since I am light at 125lbs, I figured the glass version would be perfect. If I find myself doing more flatwater, I would eventually pull the trigger on a carbon fiber ski.

ENGINE:
JetManiac/Blue Ported 781 BB(62t/61x)...painted silver
pump gas
ADA silver girdled head + girdle kit
760/ 38cc domes
Dual Cooling
Jetworks Red FCV
Lightened stock flywheel
JM Big bore port mani + headpipe
Limited B-pipe
X-metal waterbox
JM bendix- like new
JM starter- like new
New woodruff/flywheel key
New flywheel bolt
V-Force 2 cages with new reeds
stock coupler cover


CARBS:
JM tuned stock 38's with JSS bolt kit
ADA silver throttle wheel
JSS Primer kit
JSS fuel bulb
JSS Fuel pickup( in tank)
Stock Flame Arrestor with JM FA bolt kit
Stock intake manifold
replacing flat washer with locks

ELECTRONICS:
JSS rebuilt stator with stator bolt kit
JSS built MSD cables with loom
JSS start/stop switch
JSS NEW exciter coil
JSS battery cables
MSD ENHANCER
OCD dual rule 500 tidy bilges with military handlebar switch
Anti-gravity- 12 cell

STEERING/BARS ETC...
X-metal pole
Blowsion phat clamp with -1 blowsion turnplate
RRP fat riser bars- 50mm
x-metal chin pad
ODI grips
UMI throttle lever

PUMP/ DRIVELINE:
JM Reduction Nozzle- 85
Solas Mag- 144mm 12 vane non setback
Thrust Trim complete system
SBT wear ring liner
Hooker 10/16
Kawaii style couplers
JM built midshaft
JM driveshaft...new bearings, washers
Carbon Fiber rideplate


HULL:
Superfreak Front Foot Hold- carbon fiber
X metal Scupper...will run a plug when I hit the surf
JM ratchet strap
Hydroturf pole pad
Black Diamond molded turf
26mm plush + 9mm plush padding
Rear footstrap
Wamiltons engine mount washers-clear
Couch mounts
Kenney Keepers
Liquid graffix- surf straps( front and rear)
45 bilge fittings- black
45 pissers- black
No foam in the rear after some talks with previous owner, his friends, and Tem...took some convincing but I am in now.
Stock nose foam in the front
front tow loop
rear tow loop- shaefer stainless steel with backing plate








I had the toughest time getting the pump bolts in with the pump seal. I ended up having to grind down the entire soft v-flap thingy that rests up against the pump shoe...ground the flap completely off to get everything lined up.

Here's the kicker, I now have gap that seems to be the same size as the flap I ground off! Frustrating...it was probably a bit oblong in one area, causing it not to fit.

I may get another pump seal and start over or just silicone it up. Here are some pics of the gap now...with the pump in place. Gap tends to seal up near the hull side.




Pump shaft before and after shimming. Only had 1mm pump shims. 2mm was too large it seems but 1.5 seemed to be pretty good. I used a .5mm engine shim along with the pump shim just for fitment. Shaft looks pretty centered but I haven't measured it yet.


My gut is to measure...ounce of prevention saves a ton of cure but it doesnt look too bad.

What do you think?
Should I take measurements or roll with it?




Just threw the motor mounts in and mated the midshaft to the pumpshaft. The coupler rubber holder was getting in the way. I plan glassing in a SF frontfoot so I may remove it unless it's necessary. I will know more once I mock everything up.


Worked on grinding down the top loader a lot of folks recommended. My aquavein fit perfect but I need different bolts to make it work. I cut up the top loader using a sawsall with a metal blade. Took a grinder afterwords to smooth it out. Grinder wheel did not like the aluminum...it was getting hot and sticking to it but it did ok

 

[jloria]

Here's my pump alignment attempt from last weekend. I got some pointers like using ratcheting straps on the reduction nozzle hole to pull it forward.

This didn't work for me because it kept pulling the back of the pump up.

I ended up removing the reduction nozzle from the Solas mag and the wear ring to get it to line up and this did the trick. I used the long pump pumps with some spacers to ensure the wear ring stuck out far enough for the pump seal to sit on. I didn't take any pics of this unfortunately. It allowed me to get a clamp on the mag and pull it to tight with the shoe.

This is, of course, after I ground down the soft flap on the pump seal.

The pic you see here is me trying to pull the whole thing tight with the reduction nozzle against a 4x4. This had the same effect as the straps, it angled the pump up too much. That's when I removed the reduction nozzle and put the spacers + the long bolts.

Before removing the reduction nozzle for fitment:

 

[tricky1]

Looks good. Your the 4th owner so it's about time it got built. Keep up the good work.

 

[jloria]

Looks good. Your the 4th owner so it's about time it got built. Keep up the good work.

Dang!! I knew of 2 others but not a 3rd...

My main concern is that I get everything lined up properly. Thanks for the input!

 

[Crab]

You'll love the freak, I certainly do..

 

[TheBuzzard]

i'd sell my freak for the right price but it wouldnt break my heart if i kept it. me and tyrant1919 at the river today was a blast. big flips and rolls off boat wakes and the patrol boat was best. rode off into the sunset after every flip n roll! i agree with the crab, you're gonna love it.

 

[clouse22]

cool build...i too am running the solas mag in my superfreak hull. I just had to order a shorter driveshaft to get my pump to work.

Good luck with the rest of the build...looks sweet

 

[JetManiac]

Looking good, glad to see you making progress. Third pump alignment pic looks good, but new pump seal good idea.

 

[Freakrider]

Youwillfreakinlovethishullpreston !

 

[jloria]

I can't wait 'til it's finished for sure

 

[jloria]

Made more progress this weekend and will be off tomorrow for President's day. Will be at the shop again.

Pump alignment. I talked to Tem just before the weekend about installing my front foot hold. Just went over some things and we ended up discussing pump install points as well. He gave me some tips and even recommended grinding down the pump shoe just a little bit. When I started tackling the job again with a new pump seal, I ran into the same issue and didn't want to grind the shoe down. I made a decision to start trimming the pump seal flap with an xacto knife until I got the pump lined up.

It fits much better this time but there are small gaps in some areas. I am just going to leave it as is and seal up the gaps with silicone. Hopefully, I won't have any cavitation issues.

The pump is needs 1.5mm of shimming to get it lined up, but it's almost dead on so I am pretty happy with it. Again, I used 1 pump shim and 1 engine shim for now.

Jetmaniac will be sending me an assortment of shims( engine, midshaft, pump) when my carbs are ready to go.


JM's customer service:
***I ended up ordering a new pump seal from my local Yamaha dealer here. I have a specific membership and gets parts pretty cheap. It came in on Friday but 2 days before it did, JM sent one in the mail without me asking. I did say that I would be picking one up from him, but it wasn't a rush at the time. I had to call the Yamaha dealer for another reason and ended up ordering the seal. Talk about fantastic customer service from JM...class act for sure. He has helped me out a ton on this build...parts, service, tips, ideas...u name it.

Here is a pic of the simple spacers that I used to get the pump pulled as close to the shoe as possible. I removed the reduction nozzle and used a nut+washer so that I could leave the long pump bolts in. The pump bolts pull the mag to the wear ring housing, and push the wear ring out so that the pump seal can fit around it. I wanted to keep the integrity but still get some good leverage on the pump. With the reduction nozzle in, it kept angling the pump up making the alignment process worse. This was my solution and I was able to pull it as close to shoe as I could using some clamps between the mag and the pump shoe:




JD Toploader:
It took me a few hours to get the JD toploader to work on the freak. Lots of grinding and I had to buy a ton of different size metric bolts with different heads. Ended up using M6x1.00 SS button allen heads with flat and lock washers.





RD aquavein intake grate:

I also fit this one while I was in the area just so I can test the difference. This one seemed to fit much better but still needed some tweaking. I opened up some of the holes and had to grind a bit. Ended up using the same button head although I started out with a hex head cap screw.

 

[jloria]

Pump aligned...started mocking everything up before I install the FFH.



Kenny Keepers, couch mounts, surf straps...and I will be adding wamiltons washers seen here...hopefully they work...I am buying them this week.

https://www.wamiltons.com/index.php?main_page=product_info&products_id=496

 

[jloria]

Installed the JSS stator with his allen head kit, new woodruff key, JM lightened flywheel, stock flywheel bolt..Do you guys recommend I get a new flywheel bolt? Are they points of failure?

I installed these as a dry fit( no locktite, not torqued) just to get the kawaii style coupler on properly. I will go through the engine properly in the next few weekends.




**Side note...I wanted a silver engine and I got the engine way before I bought the hull. Pure coincidence that the ski was silver but it works.

 

[jloria]

Engine aligned perfectly. No shims needed. Hopefully my eyes and measurements are good.

 

[ProSouth]

Pics no worky.

 

[jloria]

Last items for today:

Trimmed down stock nose foam using a hot wire setup





B-pipe coupler:

Chamfered the edge of the coupler(JM tip)..used some windex and mated the head pipe to the chamber. Made it secure with some hose clamps to let it set up for a few days and take shape.




***RAD DUDE tube will not work on this ski with a stock tank, xmetal water box...Will be up for sale soon unless I figure something. I didn't weigh it but the tube seems lighter. Bummer.

 

[jloria]

I have some question for you guys

#1. I want to replace all my flat washers on the carbs, stator, etc... to lock washers for no movement.
Any caveats that I should be aware of?

#2. This bushing has been scored on the inside. I changed one out on my last ski a few years back but I thought it was smooth.
Is it ok to run it like this or replace it?



#3. This is my steering cable from my RN SJ.
Any special considerations on the freak?
Does it use the washer that I have the sharpie pointing at?

It kinda looked like I needed to remove it but I took a quick glance at it only.

http://www.boats.net/parts/detail/yamaha/Y-GM6-61481-00-00.html

 

[jloria]

Pics no worky.

Fixed.

Thanks!

 

[Freakrider]

Your bushing is prolly fine, they are made with that swirl in them.

 

[Sospikey]

I'd use a flat washer ALONG with the lock washer. Try to get Allen head screws for the carbs, SO worth it IMO. Nice build, man!