Octane Octane Refoam

[FlightRisk]

I'm planning on sending the flywheel away to #.2 to lighten....he said that you can lighten this flywheel by about .8 pounds of the rotating mass... that will work VERY well for me...have a set of Blackjack 46 on the way soon...so here's my rebuild list..

- Refoam
- repair hull (fix some of the wear on bottom plus thru hull bearings)
- Install trim system
- custom paint (top black bottom white)
- returf
- new carbs
- replace piston rings
- lighten flywheel
- port cyls just an additional mm on each side plus polish ex manifold

Daytona??? Maybe. I have a long way to go.

 

[FlightRisk]

Anybody have an old stock manifold they want to get rid of?

Trying to machine one to accept 46 blackjacks.

 

[Watcon]

OEM intake manifold

I have a couple of stock Keihin intake manifolds.. $50.00 each.
wcc@watcon.com

 

[FlightRisk]

I have a couple of stock Keihin intake manifolds.. $50.00 each.
wcc@watcon.com

Thanks for the help Randy, I may have to bite the bullet and grab those dual intakes from you... OUCH!!

Found some more carnage today....drive shaft was spinning inside the thru hull bearings!!! Still trying to get the shaft out of the bearings..... pics coming.

I did seal up the thru hull tunnell and put in tubing for trim nozzle.

 

[DiagNuLL]

i got the tray out of mine last night and most of the foam. about of 3rd of it was water logged. i haven't weighed the bag yet but i'm guessing its about 15 pounds :O

 

[FlightRisk]

i got the tray out of mine last night and most of the foam. about of 3rd of it was water logged. i haven't weighed the bag yet but i'm guessing its about 15 pounds :O

Sounds about right.... check your tunnel and the exhaust...both were leaky on mine. I also decided to go with polystyrene instead of the beer pong balls. According to some others, the pump inserts are the biggest culprit, they are not capped!

 

[ryan]

the exhaust on his is a yamaha superjet tube as the polaris crap one rotted out in 2 years!!! i sealed the new tube in pretty good. to bad about the rest of the leaks octanes are know 4. lol i miss that ski. but i turned it into this.

 

[FlightRisk]

the exhaust on his is a yamaha superjet tube as the polaris crap one rotted out in 2 years!!! i sealed the new tube in pretty good. to bad about the rest of the leaks octanes are know 4. lol i miss that ski. but i turned it into this.

:beerchug: Nice Ride!!

Ordering some 'peanut butter' filler and resin for the glass work today... still not sure how to handle the gunwhales...

Option A
2 part foam then sand
Place the entire cutout back into the gunwhale with footholds in tact
peanut butter filler
re glass

Option 2 (or B for those keeping up)
2 part foam then sand
Cut my footholds out of the original panel I cut out
Shape 2 part foam to foothold
Re glass the entire side

Anybody have any different options?

 

[NVGuy]

ping pong aka beer pong balls trick

I have a 03' Octane, and i am having problems with the weight, and leaks. i am wanting to redo my hull but not sure how to do it, i know fiberglass a little but by putting my foot holds in, and some other stuff. you guys are mentioning the beer pong ball trick what is it and how do i do it. also what is peanut butter filler?

 

[58vwragtop]

The beer/ping ball thing is just taking out the old foam and filling it up with ping/beer pong balls and using a little 2 part expandabe foam to stiffen and hold them all together. Im doing that with mine right now. The "peanut butter" stuff is just a cabasoil. Which is just stuff to mix in with epoxy to fill larger gaps and blend or smooth something.

 

[NVGuy]

The beer/ping ball thing is just taking out the old foam and filling it up with ping/beer pong balls and using a little 2 part expandabe foam to stiffen and hold them all together. Im doing that with mine right now. The "peanut butter" stuff is just a cabasoil. Which is just stuff to mix in with epoxy to fill larger gaps and blend or smooth something.

so your saying cut out a large piece out of your tray reseal it, add the foam, and balls, the put that same piece you cut out back in and fill the cracks with peanut butter filler, and re fiberglass where you cut it?

 

[58vwragtop]

Yea pretty much. I cut the tray, pulled the old foam out, filled the bottom of the ski with ping pong balls, then Im going to put the old tray back in using the "peanut butter" stuff to fill the voids and around the footholds then using fiberglass to reinforce. This is on my superjet, but Im also helping Kawi with his Octane. He is using poly styrene foam instead of pong balls since we didnt have enough.

 

[NVGuy]

Yea pretty much. I cut the tray, pulled the old foam out, filled the bottom of the ski with ping pong balls, then Im going to put the old tray back in using the "peanut butter" stuff to fill the voids and around the footholds then using fiberglass to reinforce. This is on my superjet, but Im also helping Kawi with his Octane. He is using poly styrene foam instead of pong balls since we didnt have enough.

when you cut it open should you seal the seams or try to find out where its leaking from? so are you just putting the ping pong balls in without any foam to keep them together?

 

[58vwragtop]

If its an Octane it leaking every where- bondline, rear exhaust tube, and around the driveshaft/bearing. When you have it cut open, use some 3M sealant on any area you think might be leaking to help seal it. I put the ping pong ball in, all 720 of them to fill the bottom part of the ski. Then I will (havent finished it yet) put the tray area back in and seal it up and fiberglass it. Then I plan on drilling some small holes in different locoations, mainly in the gunwales. Im going to mix up some 2 part foam and put it in a ketchup style container with the nozzle/tip. Then inject the foam with the container into the small holes that I drilled. This will expand to give me strength in the gunwales and behind the footholds, also it will hold the ball together and stregthen up the tray/bottom area. Then I will seal up the small holes. Ive got some pics but I dont want to thread jack Kawi's post with my ski.

 

[NVGuy]

ITS TOOK 720 BALLS TO FILL THE BOTTOM OF THE OCTANE!!! crap. does the sides of the tray you stand in need it also? how big of a hole do you need to cut in the bootom. i saw the pictures on this thread but that is huge do you think its nessasery to cut that big of a hole? can you possibly email me those pictures to me? i am needing more pictures before i do this. my email address is cennijimenez@hotmail.com Thanks

 

[FlightRisk]

ITS TOOK 720 BALLS TO FILL THE BOTTOM OF THE OCTANE!!! crap. does the sides of the tray you stand in need it also? how big of a hole do you need to cut in the bootom. i saw the pictures on this thread but that is huge do you think its nessasery to cut that big of a hole? can you possibly email me those pictures to me? i am needing more pictures before i do this. my email address is cennijimenez@hotmail.com Thanks

Trust me, if you wan't to get all the wet foam out of this tray, it takes that big of a cut.

By the way, the biggest leak in the Octanes are the pump inserts. They are not capped, and water can enter the tray there.

Just kiddin! you can post the pics of your ping pong ski in this thread all day long. I have not done much on mine lately, but starting up again this week. :Banane01:

 

[NVGuy]

when i cut into the tray do i have to be careful that i dont cut into anything? also if i didnt want to do the ping pong ball trick what foam should i use when i put it back together?

 

[Highroller]

You don't want to use a long blade because you can cut your cooling lines or driveshaft housing. I would use a dremal or cutoff wheel to be safe and just breakthrough the otherside, don't go much deeper.

Instead of ping pong balls you could use pop bottles. This works great and you can still add the foam. the pop bottles take up a good amount of room to save the weight of the foam.

I like 4lb US composites 2 part expanding urthane foam. The 8lbs foam is also good. The gallon kit will get the job done. uscomposites.com

 

[NVGuy]

i decided im not going to do the ping pong ball trick, instead i am going to do foam. how much foam do you think i will need to do the bottom of the tray and the sides?

 

[DiagNuLL]

i bought a 2 inch thick sheet of Extruded Polystyrene from Lowes for $30 and cut it into blocks as needed to fill the bottom of the hull. i've taken a few pics along the way, i'll resize them and get them posted.

you really do need to be careful cutting to deep into the tray, cooling lines, mid shaft, and exhaust could all get nicked if you aren't careful.