Project 440 freeride

[bungeeguy]

I started out on an old js550 and have always wanted to have another one BUT it had to have a few changes. I just picked up a 1981 js440 and I'm in the process of bringing it back to life as a fun freeride ski. Mostly I wanted a wider tray and shorter hand pole. I bought the ski for $120 bucks and it came with some really nice parts, pjs exhaust, aluminum waterbox and westcoast midshaft/bulkhead brace. The hull is pretty rough but I'm chopping it up and glassing anyway. The goal on the entire project is to be at or under $400 when I'm all done. I have a free 550 motor coming from a buddy and I picked up a high compression head for $25. The glass and epoxy so far has run me about $50.
For anyone wondering, the ski in the back is a carbon Rickter Edge. I'm running a Dasa 1100 with a skat mag 148 pump, it is awesome but you never forget your roots.

 

[bungeeguy]

I've been cutting this week and getting close to being done with the glass. I modeled the tray after my Rickter, it is almost the same width and depth, I also cut back and reshaped the rear or the bunks and cut about 8.5 inches out of the stock pole.

 

[bungeeguy]

For the bunk rails I sandwiched press board between the fiberglass and then refilled with expanding foam, I was very impressed with how strong everything came out. I will spend the next few days sanding to clean everything up and once the temps are warm enough be painting it a dark grey metallic and adding stock style graphics from the 70's era. It should look basically like a stock ski but handle much better.

 

[jetskijockey]

Can you post more pics on that handlepole? Nice work!

 

[bungeeguy]

I will get a few on Sunday and post. I basically just removed the sides and then stacked the two ends together with glass and resin between each piece then riveted them together and glasses the sides. Should be way stronger than it ever was stock but still look like a stock pole

 

[dose]

subscribing to this!!
keep the pictures coming
I love the JS hulls, and want to wide tray mine this winter too

 

[bungeeguy]

Handpole. Its at filler stage now and will be getting painted soon

 

[bungeeguy]

Some of the parts that came with.

 

[The440Dude]

Subbed

 

[afraz1er]

subbed.

couldnt agree with you more on getting back to your roots, been slowly building a 550 myself. 2" off the back. reshaped rear of tray. removed the rear sponsons, widened the tray, blah blah

 

[bungeeguy]

It has been warm enough to put down some paint and will have the turf done in a couple days

 

[Slowx2]

Looks like a fun project. Cant believe how cheap you are building it for.

 

[The440Dude]

Im really interested in how it rides with the the new hand pole. Id like to take 4 inches off mine. Will you still be using the stock throttle/steering cables?

 

[bungeeguy]

Im really interested in how it rides with the the new hand pole. Id like to take 4 inches off mine. Will you still be using the stock throttle/steering cables?

With the pole on the stock cables will work just fine. Because the motor is out right now I can put the cables wherever I want so using up a little more space isn't an issue.

 

[bungeeguy]

Pole on and turf started

 

[The440Dude]

Pole length looks good!

 

[Js550FTW]

Wow! This looks awesome! I expect a backflip attempt lol

Sent from my LG-LS970 using Tapatalk

 

[_evan]

Yowza that pole looks good. Interesting to hear how much different it rides when it's finished. I need to see some ride pics and opinions on the pole length. I have a pole I have been wanting to do this to

 

[Nottjbarlow]

Been wanting to try a shorter pole on my 550 for the longest time....

Getting tired of my pp550 power plant, time for the 750 swap