- Location
- Ocala, FL
Its a lot to read but I figured I'd document what I've done. If I manage to complete this most of you guys with any experience should be able to mange the swap with no problems!
Started my pump swap but havent had as much time as I had hoped to work on it. Im not all that confident in the work im doing but it seems to be coming together. Mainly just glassing and aligning left. Im using polyester resin and glass glass from homedepot which is pretty thin stuff so im making sure to build it up a good bit and ive sanded down to glass around everywhere ive glassed in hopes to make a nice bond. The only problem ive had so far was the foam. Not only did I use a bit much and ended up with lots of pockets, I guess it wasnt fully cured when i started shaping it and it distorted overnight. I sand it the mounting surface level after letting the foam sit at least a day and then let it sit overnight before glassing it it had a few low spots. I deciced id just build up more glass in those spots instead of trying to work with the foam more. This made the first layer of glass a bit difficult to lay but hopefully all will be well once i clean it up and lay some more on.
Here is what ive done:
Got the stock pump/shoe/midshaft housing out.
My dad got my bearing pressed in for me at work today.
Ground out some room for the 140mm pump (god it took forever, not a job for a dremel...)
Glassed up the holes from the stock mounts
Pulled out a decent bit of foam, all bone dry except a tiny but of water near the cooling tube.
Bought some Great Stuff foam and filled the voids back up.
Cut the foam back, realized there were quite a few big air pockets
Glassed over part of the foam with just one layer of real thin glass.
Unfortunately spring break is over so i wont be back to work on it for another week of two but heres my plan:
Get the couplers swapped over, push in the seals and bolt the midshaft housing back up.
Build up the pump mounting surface and level it out.
Figure out how to align the pump correctly.
Glass up the sidesof the intake that i ground down.
Install pump mounts (got some SS inserts from ACE Hardware and also recovered the stock mounts.)
Paint it black
Install my prop
Bolt up the pump and smooth everything out with some 5200
Order the inserts for my straps and glass them in.
Ride?
And somewhere in there i gotta figure out how the cooling, steering, and trim is gonna work.
Some pics of the mess ive made
Grinding done (I think)
http://img217.imageshack.us/i/img1441o.jpg
Holes left from the stock mounts
http://img20.imageshack.us/i/img1446ul.jpg
The sides of the cavity with some foam removed
http://img837.imageshack.us/i/img1447c.jpg
The holes glassed over, this part went pretty smooth it seemed
http://img690.imageshack.us/i/img1454x.jpg
Sprayed in my canned foam (a good bit too much of it)
http://img268.imageshack.us/i/img1457gr.jpg
Foam expanded
http://img69.imageshack.us/i/img1458o.jpg
Shaved it down with a hacksaw blade at first then wither with the dremel or just a sander
http://img14.imageshack.us/i/img1461m.jpg
First layer of glass on the uneven foam, this is the main part im not happy with but it should be fine once i build it up more
http://img31.imageshack.us/i/img1462e.jpg
The right side turned out ok, it had more high spots then low spots so i just sat a piece of wood wrapped in a grocery bag on top with a little weight on it while it cured which leveled it out pretty well. The a couple big low spots so i just did my best to get it to bond everywhere and ill layer some chop may of something in the low spots
Started my pump swap but havent had as much time as I had hoped to work on it. Im not all that confident in the work im doing but it seems to be coming together. Mainly just glassing and aligning left. Im using polyester resin and glass glass from homedepot which is pretty thin stuff so im making sure to build it up a good bit and ive sanded down to glass around everywhere ive glassed in hopes to make a nice bond. The only problem ive had so far was the foam. Not only did I use a bit much and ended up with lots of pockets, I guess it wasnt fully cured when i started shaping it and it distorted overnight. I sand it the mounting surface level after letting the foam sit at least a day and then let it sit overnight before glassing it it had a few low spots. I deciced id just build up more glass in those spots instead of trying to work with the foam more. This made the first layer of glass a bit difficult to lay but hopefully all will be well once i clean it up and lay some more on.
Here is what ive done:
Got the stock pump/shoe/midshaft housing out.
My dad got my bearing pressed in for me at work today.
Ground out some room for the 140mm pump (god it took forever, not a job for a dremel...)
Glassed up the holes from the stock mounts
Pulled out a decent bit of foam, all bone dry except a tiny but of water near the cooling tube.
Bought some Great Stuff foam and filled the voids back up.
Cut the foam back, realized there were quite a few big air pockets
Glassed over part of the foam with just one layer of real thin glass.
Unfortunately spring break is over so i wont be back to work on it for another week of two but heres my plan:
Get the couplers swapped over, push in the seals and bolt the midshaft housing back up.
Build up the pump mounting surface and level it out.
Figure out how to align the pump correctly.
Glass up the sidesof the intake that i ground down.
Install pump mounts (got some SS inserts from ACE Hardware and also recovered the stock mounts.)
Paint it black
Install my prop
Bolt up the pump and smooth everything out with some 5200
Order the inserts for my straps and glass them in.
Ride?
And somewhere in there i gotta figure out how the cooling, steering, and trim is gonna work.
Some pics of the mess ive made
Grinding done (I think)
http://img217.imageshack.us/i/img1441o.jpg
Holes left from the stock mounts
http://img20.imageshack.us/i/img1446ul.jpg
The sides of the cavity with some foam removed
http://img837.imageshack.us/i/img1447c.jpg
The holes glassed over, this part went pretty smooth it seemed
http://img690.imageshack.us/i/img1454x.jpg
Sprayed in my canned foam (a good bit too much of it)
http://img268.imageshack.us/i/img1457gr.jpg
Foam expanded
http://img69.imageshack.us/i/img1458o.jpg
Shaved it down with a hacksaw blade at first then wither with the dremel or just a sander
http://img14.imageshack.us/i/img1461m.jpg
First layer of glass on the uneven foam, this is the main part im not happy with but it should be fine once i build it up more
http://img31.imageshack.us/i/img1462e.jpg
The right side turned out ok, it had more high spots then low spots so i just sat a piece of wood wrapped in a grocery bag on top with a little weight on it while it cured which leveled it out pretty well. The a couple big low spots so i just did my best to get it to bond everywhere and ill layer some chop may of something in the low spots
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