- Location
- New Zealand
This build was started a while ago but thought i would upload it to the X this is where i have found lots of ideas for my build and before its finished for any other good ideas.
Mid 2012:
Well I thought I might as well start a build thread of my first ski, 96 Yamaha superjet.
Before:
Mods before:
Hull: Blowsion Tubbies
Pump & Handling: Solas concord 13/17
Blowsion freestyle pump cone
Composite D-cut ride plate
Worx 205 intake grate
Stock pump with dual cooling
Stock reduction nozzle bored to 85mm, bilge siphon removed
Custom s/s turn nozzle
Engine: ADA Girdled head
MSD plug caps
Speed worx pipe
Jetworks standard flow control valve
Boyseen Reeds
Other bits: 500 GPH Bilge Pump
Custom s/s battery tray
ODI lock-on grips
MB16U battery
Build plan / story: Well it was just going to be footholds, turf, and reinforce hull and that’s it. Because riding in the surf without footholds is a bit dumb I thought. Engine was pretty good with the current mods.
So I did some research on the net to see what footholds to go with, there’s so many to choose from. I was originally going to go with adjustable or make some custom adjustable ones, but they are a bit pricey for me, so I went with WDK REV’s (Water-Dawg Kustoms) they looked pretty good and had good feedback.
Then from there one thing leads to another and my bank acc started depleting….
A few more goodies from WDK, lowered hood, nose piece and lowered pole bracket.
When I put my speedworx pipe in I didn’t really know what I was doing so I was still running single cooling for engine and pipe. Pipe made a big difference to power but everything was running rather hot and things were playing up a bit, also had problems with split sparkplug caps which took us a while to figure out what was wrong until I was flushing out the ski and started to get shocks off the leads.
So replaced caps with MSD ones, tapped pump for dual cooling and I was away laughing, she never missed a beat after that.
So started striping out the ski, and had everything sitting in garage for weeks as I had lots of study to get done and ski went on hold.
Then in between study and work I just did little bits here and there and ended up pulling off the head and having a looksee and found some pretty bad scoring in the rear cylinder, i could have just given the bore a bit of a clean-up and new rings, but that’s a bit rough for me.
Because the scoring was pretty deep decided to take it up to a 718cc and got some new pro-x pistons (82mm). So while I was at that stage I thought I would port match the sleeves and do some gasket matching on the exhaust ports and manifold.
Then why not do some case porting, so split the case and had a look at crank seals and bearings, main crank bearing was a little noisy so thought I should replace it and seals just in case because I’ve got this far may as well, hate to put it back together and it s itself.
Did some light porting on cases, I might epoxy the case so if I ever want to go more I can or I might do a bit more before I put it all back together not sure yet.
And fly cut sleeves. There looks like there’s heaps of different ways to shape these to increase bottom end or top end, I hope I haven’t taken too much and lost bottom end, should be sweet.
Got my pro-x pistons and got the cylinders bored. The pistons looked a bit uninviting when I took them out of the box so gave them a little polish.
Engine out:
New mods and plan to do:
Hull: WDK Rev footholds (all WDK products are mint, very high quality)
WDK RAZR freestyle hood with nose cone
Dakine front foot strap or front foot-hold
’’ Angle cut rear, I was keen to put some rocker in the front too, but that’s way too much work when summers just around the corner, and how far do you want to go when you could get a AM hull with all the bells and whistles that’s half the weight, so I’ll keep it simple… ish
De-foam as I have found today when pulling out exhaust tube she’s a bit waterlogged but that’s understandable for a ski of this age. So going to foam around footholds and put polystyrene blocks in bottom and add in drainage holes.
Add in tube for trim cable
Reinforce in all necessary places
External fuel fill remove
Pump and handling:
Replace all driveline bearings and seals as a few were stuffed
Shorten ride plate to match hull or where every feels good
Trim reduction nozzle bored to 85mm
X-metal trim system with custom trim ring (way lighter compared to x-metal one)
Worx 201 grate
Blueprint Stock pump (lots of work don’t really think its guna make that much of a difference myself, but some people reckon it’s the goods, at least I managed to save 20grams of weight, lol).
Lighten stock couplers (probably not the best idea as they are only cast, we’ll see how long they last didn’t take much out of them)
New custom s/s turn nozzle, as I need a bigger one to fit over trim ring.
Steering: Knoxie Products pole
Shortened turn plate
Straight bars
Lowered pole bracket
Engine:
718cc 82mm pro-x, port matched, gasket matched, case porting
Lightened stock flywheel
Crank seals and bearing
Stock water box, make it bling
KP engine keepers
V-Force reeds and cages
Custom Ali fuel cell with internal filler or a plastic kart tank (not sure yet)
Replace a couple of engine mounts
some bolts will be replaced with stainless (the ones you see and non - important / torque setting), heads high polished (more bling gotta make you ride better)
Paint: Bright orange with black graphics.
High tech designing in windows paint:
Other bits: Upgrade bilge pump (2x 500gph)
Maybe new Ali battery tray
Ratchet hood strap to keep that AM hood rock solid.
Cold fusion hood hooks
Reinforced stock hood prongs
And more stuff I’ll come up with along the way.
Got most of the engine parts and bit n pieces from Jetmaniac (Best one stop shop for parts) and turf etc from AJSP
So haven’t got very far yet since the ski has been apart for almost 6months now, just need to get study done then will be right into it.
Next post - november 2012:
Ok so finished all my study now, And it’s pretty much summer and want to ride.
Update on what I’ve got done so far:
Cut tray open wasn’t quite planning on cutting it open this much but if your gunna do it I say do it properly. Bit of a change in plan with the tray, going to re-foam the whole thing, carve a new wide tray out and glass over the foam.
Defoamed etc. (Dug, sawed, hacked and finally water blasted it all out)
Angle cut rear transom -3.5’’
Cut these bad-boys out for bit more space and to ensure bulkhead was going to be completely water tight.
Got rid on as much of the green glue as possible and coved the fillet so I could get some nice glass in there.
Sanding nose out and inside of the external filler to try take out some weight and make it look even with the other side.
Bogged up all bond lines deck and engine bay, sanded ribs etc. & Ruffed everything up with 36grit.
Glassed around the whole hull. Two layers of cloth on engine bay sides, one on the tray sides and 3 to 4 in nose and under pole bracket etc. wrapped the glass under the hood seal lip too. (She’s pretty solid) Bogged external gas filler.
Cut some of that real-estate signage board stuff and waxed one side and taped it on and glassed from inside.
It turned out pretty good. It’s about 7mm thick.
Next the front foot hold. Originally was going to do a front foot strap but quite liked the idea of something along the lines of these:
So I made a ply box, resined the inside, poured in some two pot urethane foam, made a nice square block and started carving away a foot hold.
Ended up with that. Resined it up and that’s my mold.
Exhaust, I wanted a nice flush pipe at the rear with nothing external on the transom, so I decided on an internal flange with 3 bolts so it could be done up tight, because I do not want this to leak at all, unlike the stock one.
Tapped into flange, counter-sunk outside and bogged over the screw heads.
Had to weld the flange while it was in the ski, as the swaged end of the tube doesn’t fit through the bulk-head hole.
Slowly getting there.
Current update Today:
Ok long time since an update, should really have it all finished by now. Progress has been slow but been trying to do it all nicely.
Aim now is to get it all done by the end of March so I get some time to try to learn how to ride again before www.nzfestivaloffreeride.com in April.
Finally finished all the glass work. Originally planned to just go with rear footholds and was trying to make up my mind between front foothold and a foot strap. Foot strap would have probably been better but after already making a mould for foot hold I decided to go with it. Also i quite liked the look of the Krash industries double foothold, even though never actually ridden a ski with them. So why not combine the two together.
Have started and now finished painting engine and aluminium parts.
E-line 379 paint.
Garage converted into spray booth
Yes I had planned to polish the water box which I did but polished ali goes a bit with salt water after a while (too high maintenance to keep nice) and paint turned out pretty good. Did the same with the speedwerx pipe painted aluminium colour (will post more pics in next update).
After fishtailing/cutting the rear of the ski for the trim I had no rear tie-down eyelet so made these and fixed them into the transom area.
Still got a bit more sanding etc. on the hull but if I pull finger should be ready for primer after the weekend.
Some pics of the fun I had with foaming the tray:
And if you are wondering why didn’t he make the footholds symmetrical/another foothold, hadn’t planned on doing the double foothold and I should have lowered the exhaust, but it’s all good still plenty of room and don’t really ride with my foot over though ways.
Have got some 20mm EVA foam for under the turf to make it a bit softer and some 8mm for around the holds.
Engine is pretty much ready to go back together just a few little bolts and brackets to polish. Got some new engine mounts on the way from Dave at 701 industries, very cool having a selection of colours to choose from, got the orange ones.
Ali plate made for under pole bracket:
The waterdawg bracket didn’t quite leave enough room for the cold fusion hood hooks so had to mill a little bit off the sides of the pole bracket as I didn’t want to lay into this machined beauty with the linisher.
Mid 2012:
Well I thought I might as well start a build thread of my first ski, 96 Yamaha superjet.
Before:
Mods before:
Hull: Blowsion Tubbies
Pump & Handling: Solas concord 13/17
Blowsion freestyle pump cone
Composite D-cut ride plate
Worx 205 intake grate
Stock pump with dual cooling
Stock reduction nozzle bored to 85mm, bilge siphon removed
Custom s/s turn nozzle
Engine: ADA Girdled head
MSD plug caps
Speed worx pipe
Jetworks standard flow control valve
Boyseen Reeds
Other bits: 500 GPH Bilge Pump
Custom s/s battery tray
ODI lock-on grips
MB16U battery
Build plan / story: Well it was just going to be footholds, turf, and reinforce hull and that’s it. Because riding in the surf without footholds is a bit dumb I thought. Engine was pretty good with the current mods.
So I did some research on the net to see what footholds to go with, there’s so many to choose from. I was originally going to go with adjustable or make some custom adjustable ones, but they are a bit pricey for me, so I went with WDK REV’s (Water-Dawg Kustoms) they looked pretty good and had good feedback.
Then from there one thing leads to another and my bank acc started depleting….
A few more goodies from WDK, lowered hood, nose piece and lowered pole bracket.
When I put my speedworx pipe in I didn’t really know what I was doing so I was still running single cooling for engine and pipe. Pipe made a big difference to power but everything was running rather hot and things were playing up a bit, also had problems with split sparkplug caps which took us a while to figure out what was wrong until I was flushing out the ski and started to get shocks off the leads.
So replaced caps with MSD ones, tapped pump for dual cooling and I was away laughing, she never missed a beat after that.
So started striping out the ski, and had everything sitting in garage for weeks as I had lots of study to get done and ski went on hold.
Then in between study and work I just did little bits here and there and ended up pulling off the head and having a looksee and found some pretty bad scoring in the rear cylinder, i could have just given the bore a bit of a clean-up and new rings, but that’s a bit rough for me.
Because the scoring was pretty deep decided to take it up to a 718cc and got some new pro-x pistons (82mm). So while I was at that stage I thought I would port match the sleeves and do some gasket matching on the exhaust ports and manifold.
Then why not do some case porting, so split the case and had a look at crank seals and bearings, main crank bearing was a little noisy so thought I should replace it and seals just in case because I’ve got this far may as well, hate to put it back together and it s itself.
Did some light porting on cases, I might epoxy the case so if I ever want to go more I can or I might do a bit more before I put it all back together not sure yet.
And fly cut sleeves. There looks like there’s heaps of different ways to shape these to increase bottom end or top end, I hope I haven’t taken too much and lost bottom end, should be sweet.
Got my pro-x pistons and got the cylinders bored. The pistons looked a bit uninviting when I took them out of the box so gave them a little polish.
Engine out:
New mods and plan to do:
Hull: WDK Rev footholds (all WDK products are mint, very high quality)
WDK RAZR freestyle hood with nose cone
Dakine front foot strap or front foot-hold
’’ Angle cut rear, I was keen to put some rocker in the front too, but that’s way too much work when summers just around the corner, and how far do you want to go when you could get a AM hull with all the bells and whistles that’s half the weight, so I’ll keep it simple… ish
De-foam as I have found today when pulling out exhaust tube she’s a bit waterlogged but that’s understandable for a ski of this age. So going to foam around footholds and put polystyrene blocks in bottom and add in drainage holes.
Add in tube for trim cable
Reinforce in all necessary places
External fuel fill remove
Pump and handling:
Replace all driveline bearings and seals as a few were stuffed
Shorten ride plate to match hull or where every feels good
Trim reduction nozzle bored to 85mm
X-metal trim system with custom trim ring (way lighter compared to x-metal one)
Worx 201 grate
Blueprint Stock pump (lots of work don’t really think its guna make that much of a difference myself, but some people reckon it’s the goods, at least I managed to save 20grams of weight, lol).
Lighten stock couplers (probably not the best idea as they are only cast, we’ll see how long they last didn’t take much out of them)
New custom s/s turn nozzle, as I need a bigger one to fit over trim ring.
Steering: Knoxie Products pole
Shortened turn plate
Straight bars
Lowered pole bracket
Engine:
718cc 82mm pro-x, port matched, gasket matched, case porting
Lightened stock flywheel
Crank seals and bearing
Stock water box, make it bling
KP engine keepers
V-Force reeds and cages
Custom Ali fuel cell with internal filler or a plastic kart tank (not sure yet)
Replace a couple of engine mounts
some bolts will be replaced with stainless (the ones you see and non - important / torque setting), heads high polished (more bling gotta make you ride better)
Paint: Bright orange with black graphics.
High tech designing in windows paint:
Other bits: Upgrade bilge pump (2x 500gph)
Maybe new Ali battery tray
Ratchet hood strap to keep that AM hood rock solid.
Cold fusion hood hooks
Reinforced stock hood prongs
And more stuff I’ll come up with along the way.
Got most of the engine parts and bit n pieces from Jetmaniac (Best one stop shop for parts) and turf etc from AJSP
So haven’t got very far yet since the ski has been apart for almost 6months now, just need to get study done then will be right into it.
Next post - november 2012:
Ok so finished all my study now, And it’s pretty much summer and want to ride.
Update on what I’ve got done so far:
Cut tray open wasn’t quite planning on cutting it open this much but if your gunna do it I say do it properly. Bit of a change in plan with the tray, going to re-foam the whole thing, carve a new wide tray out and glass over the foam.
Defoamed etc. (Dug, sawed, hacked and finally water blasted it all out)
Angle cut rear transom -3.5’’
Cut these bad-boys out for bit more space and to ensure bulkhead was going to be completely water tight.
Got rid on as much of the green glue as possible and coved the fillet so I could get some nice glass in there.
Sanding nose out and inside of the external filler to try take out some weight and make it look even with the other side.
Bogged up all bond lines deck and engine bay, sanded ribs etc. & Ruffed everything up with 36grit.
Glassed around the whole hull. Two layers of cloth on engine bay sides, one on the tray sides and 3 to 4 in nose and under pole bracket etc. wrapped the glass under the hood seal lip too. (She’s pretty solid) Bogged external gas filler.
Cut some of that real-estate signage board stuff and waxed one side and taped it on and glassed from inside.
It turned out pretty good. It’s about 7mm thick.
Next the front foot hold. Originally was going to do a front foot strap but quite liked the idea of something along the lines of these:
So I made a ply box, resined the inside, poured in some two pot urethane foam, made a nice square block and started carving away a foot hold.
Ended up with that. Resined it up and that’s my mold.
Exhaust, I wanted a nice flush pipe at the rear with nothing external on the transom, so I decided on an internal flange with 3 bolts so it could be done up tight, because I do not want this to leak at all, unlike the stock one.
Tapped into flange, counter-sunk outside and bogged over the screw heads.
Had to weld the flange while it was in the ski, as the swaged end of the tube doesn’t fit through the bulk-head hole.
Slowly getting there.
Current update Today:
Ok long time since an update, should really have it all finished by now. Progress has been slow but been trying to do it all nicely.
Aim now is to get it all done by the end of March so I get some time to try to learn how to ride again before www.nzfestivaloffreeride.com in April.
Finally finished all the glass work. Originally planned to just go with rear footholds and was trying to make up my mind between front foothold and a foot strap. Foot strap would have probably been better but after already making a mould for foot hold I decided to go with it. Also i quite liked the look of the Krash industries double foothold, even though never actually ridden a ski with them. So why not combine the two together.
Have started and now finished painting engine and aluminium parts.
E-line 379 paint.
Garage converted into spray booth
Yes I had planned to polish the water box which I did but polished ali goes a bit with salt water after a while (too high maintenance to keep nice) and paint turned out pretty good. Did the same with the speedwerx pipe painted aluminium colour (will post more pics in next update).
After fishtailing/cutting the rear of the ski for the trim I had no rear tie-down eyelet so made these and fixed them into the transom area.
Still got a bit more sanding etc. on the hull but if I pull finger should be ready for primer after the weekend.
Some pics of the fun I had with foaming the tray:
And if you are wondering why didn’t he make the footholds symmetrical/another foothold, hadn’t planned on doing the double foothold and I should have lowered the exhaust, but it’s all good still plenty of room and don’t really ride with my foot over though ways.
Have got some 20mm EVA foam for under the turf to make it a bit softer and some 8mm for around the holds.
Engine is pretty much ready to go back together just a few little bolts and brackets to polish. Got some new engine mounts on the way from Dave at 701 industries, very cool having a selection of colours to choose from, got the orange ones.
Ali plate made for under pole bracket:
The waterdawg bracket didn’t quite leave enough room for the cold fusion hood hooks so had to mill a little bit off the sides of the pole bracket as I didn’t want to lay into this machined beauty with the linisher.