MY Square nose Superjet build

[WFO Speedracer]

I probably shouldn't be starting this thread because I have two others going already and progress on this one will be really slow, but alas it has been started so here goes. Square nose Superjet hull that I got disassembled in boxes, I traded a Waveruner lll hull for it some years ago. So all the missing pieces need to be rounded up, of course I have all the basic stuff here 701x engine , exhaust pipe and carb and a 144 pump. I need a driveshaft and possibly a midshaft an intake grate and a ride plate.

The plan is to build the ski like I am going to keep it, honestly I have never really liked Superjets that much but I decided to build this to my specs, set it up like I want it and give it a fair shake, the worst that can happen is I like it, if not someone ends up with a really nice ski with all the bugs worked out, I really can't go wrong either way.

In my quest for parts I also ran across a Carter B rocker kit a friend of mine was selling so I bought it thinking it could be made to work on the square nose ski, it does work with some cutting and mods as in the pics below. This ski had footholds they were not put in properly and the foam is waterlogged so that's next on the list. the ski also has a rear scupper installed with a one way valve , I am leaving that as is.

Even though it had rear exhaust some idiot bought a Blowsion exhaust exit and put the exhaust on the right side of the ski, I removed the exit and sold it and glassed in the hole .Here is where it sits right now, front has been chopped off and the rockered nose kit installation has been started , and yes that is a 300SX handlepole I am probably installing on the ski, more on that later.

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[WFO Speedracer]

I was able to get a ride plate, midshaft, driveshaft and intake grate from members here and on PWCT ,
I found a guy on Ebay that makes custom Derlin bushings to your specs, so I am measuring everything up and sending him the info, this will make the handlepole a bolt on affair using the stock mount and handlepole bolt , of course I will have to change out the subplate to one that accepts regular handlebars.

That will get it onto the mounts , there are some more alterations that will need to be done to make it fit the hood and I will need to add a piece to the front of the cover to mask the pivot area, I should have a spare cover left over from my 300SX conversion ski that I can use for that purpose.

 

[WFO Speedracer]

I found a guy on Ebay that makes custom Derlin bushings to your specs, so I am measuring everything up today and sending him the info, this will make the handlepole a bolt on affair using the stock mount and handlepole bolt , of course I will have to change out the subplate to one that accepts regular handlebars.

That will get it onto the mounts , there are some more alterations that will need to be done to make it fit the hood and I will need to add a piece to the front of the cover to mask the pivot area, I should have a spare cover left over from my 300SX conversion ski that I can use for that purpose.

 

[WFO Speedracer]

300SX sublplate modded to fit regular bars, this was not a fun process, first I ground the rivets flush then I drilled through them, then I mounted the plate in a vice and heated the holders and with a large pipe wrench I was able to get them free, but I also had to drill through the holes in multiple places then heat, twist the bars with the pipe wrench and hammer on the pipe wrench to get them out.

I cut the aftermarket bars at the vee bend equal on both sides, then I found a spade bit and ground off the point, I resharpened the end and sharpened the two sides and guided it through the holders, I also had to file the bars down and hit them with sandpaper to get them to go back into the holders, i had to hammer them back in and I will most likely drill the bars and tap them through the rivet holes to accept flat head allen screws for retention.

 

[WFO Speedracer]

And the two have now become one, I am really amazed at how close the body lines are going to be, there will be minimal fairing and filling on this one.

 

[WFO Speedracer]

For those of you not familiar the 300SX pole is actually aluminum, the rest is just a plastic cover, so by getting rid of the side angle on the plastic cover and reglassing the sides straight it fits the SN hood like a glove.

I duct taped the sides together, then using the table saw I made some spacers and then I laid the glass to it. I am seriously considering gluing the sides to the pole and calling it done, I can still install the plastic cover on the bottom or I may glass it back together still thinking on this one.

 

[WFO Speedracer]

I have the ski hung up on the Gantry crane but when I did I noticed that the right side is stuck very well but the left side is not, normally I would cut away the non stuck part but I am going a different route here, I am going to get some 8lb or 16 lb pour foam and pour it in and let it expand, that will fill in the area and add some strength then I can taper the edge back and start glassing, now I just have to wait for the foam to get here.

I am also mixing up some more epoxy -cabosil and smoothing out the front area inside so I have a nice transition to glass to.

 

[WFO Speedracer]

I received the handlepole bushings today and they fit perfectly, if anyone ever needs something like this made I highly recommend delrindepot-4 on Ebay, I will post some pics tomorrow.

 

[WFO Speedracer]

a couple of pics of the bushings and one with everything together, I might catch some flack for this but I am leaving the pole pad , I kinda dig it ! The two pieces sticking out the top of the hood are going to be used to cover up the holes where the vents were, vents get moved to the back and the front air holes get blocked off as well, I may put a few small air holes back where the vents used to be not sure just yet

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[WFO Speedracer]

And that brings it up to where I am right now, time to defoam and refoam this b!tch, I bought a bunch of sheets of 1 1/2 thick blue foam from some guys who were tearing down chicken houses, locally most of it was in really nice condition and was used on my house up by the lake but I have plenty of scrap and a sheet of new 3/4 ' foam left over left over to refoam this with.

 

[Quinc]

what potato are you taking these pics with? They are blurry and thumb nail sized. Lots of good info though! Had no idea about the 300sx pole being that close of a fit.

 

[WFO Speedracer]

My phone which is all I have right now these new pics should be better, at any rate this is an old three wheeler trailer I bought last year , I got it because it was very cool and unusual, I use it haul my Yamaha BIG WHEEL 200 and thought with some mods it could be used to haul standups, so today I cut up some Trex 2X4 s and notched them on the table saw, I used four of the existing mounting holes and drilled three more per side using stainless eye bolts in front and back for tie down locations.

Trex is not usually used for bunks because it has to have a lot of support, it bends easily and it won't support weight over a span but if you notch it and bolt it to a piece of angle iron it's tough as nails. I slit a piece of PVC on the table saw and slipped it over the front pipe, I will also put some type of rubber over the PVC. I will probably slit some bigger PVC tubing and slip it over those sections in the back as well.

I ground down the corners on the front and rounded them so I wouldn't get caught on them, it is a little tongue heavy but that means it will pull down the road nicely and I will just add a tongue jack. I am digging it, it should make launching really easy especially in my pond . I am going to have to get a drop hitch to pull this with as the angle as is is way too steep on my truck.

 

[WFO Speedracer]

I was looking for an option for a hook to secure the front since the bow eye is now history , some of my other skis just have a stainless steel bow hook but I don't like the way it juts out so I wanted something removable , that's when I remembered the removable tie downs for truck beds made by Ancra industries, I will probably have to replace the hardware and make a stainless steel or aluminum backup plate but I think this will work, if not I can find another use for it, I may recess it into the hull a bit and it will probably get painted with the hull.

Welcome to RV and Auto Parts - Great Selection at Friendly Prices

 

[WFO Speedracer]

No pics today , weather is miserable here with a heat index of 111 only good for one thing, laying fiberglass , so I did one side on the bottom , flipped it over did the bottom and now I have flipped it again and I did the other side on the bottom, all will be fully cured by dark today, then I do a few places inside the ski and it is ready to refoam and finish with fairing compound.

A little trick I learned along the way was to spray the hull and the glass with 3M Super 77 adhesive, then glue the glass down to the hull, now you can concentrate on getting the it wetted out and getting the air bubbles out without it lifting and moving around every time you touch it.

 

[jpswift1]

Love the BW200! I have one that I restored to like new condition. I also have a TW200. Those fat tire bikes are a blast.

 

[WFO Speedracer]

I have the BW200 and two TW 200' s , I am just riding the BW as a beater right now but the plan is to restore it and sell it, prices are at an all time high on those right now, I am also restoring one of the TW's the other one I am doing something custom with since it is missing so many parts, maybe a tracker build but basically it will be my next beater for a while

 

[jpswift1]

I have the BW200 and two TW 200' s , I am just riding the BW as a beater right now but the plan is to restore it and sell it, prices are at an all time high on those right now, I am also restoring one of the TW's the other one I am doing something custom with since it is missing so many parts, maybe a tracker build but basically it will be my next beater for a while

If you come across a BW350, those are the ones really bringing crazy high dollars. They're VERY heavy bikes though.

 

[Sanoman]

Nice build! You have all the tricks to get the build done.Sub’d

 

[WFO Speedracer]

I am trying to figure out how I want to terminate the rub rails at the front so I made a mold with duct tape and poured some 8 lb foam, I will have to play around with it and see if I can get a shape that I like then I will glass over it, remove the foam and finish glassing from the underside of the ski. Then I get to start on the other side and do it all again.

 

[WFO Speedracer]

Nice build! You have all the tricks to get the build done.Sub’d

Thanks I have followed your builds through the years as well , you build some really nice clean stuff.