Custom/Hybrid SuperFreak,my little nightmare

[Sanoman]

The hull l'm getting ready to redo some different areas on is a predecessor to what ended up being a SF Bad Ass.More Super Jet-ish than a SF.l think Tem was still at Xscream before parting ways and going out on his own.

So this hull is glass,which made it just the right weight in the surf.Other than adding tubbies,l just dropped all my components in it and have run it ever since.Been awesome having a ski that didn't matter if it got a scratch on it.Run it up on the beach,just didn't care.But several things have needed attention.

1.The hump at the rear of the gunwales is too high for my elbows and the low part of them made it hard from me to plant my elbows to reach the bars.No short people jokes please! We have feelings too.
2.Tubbies need to be glassed in.
3.The inserts for all the engine components are weak and need some more reinforcement.

So today l removed the turf from the tray to see what l had.Layed some masking tape down to get some kind of idea where l need to add and cut the gunwales out to make them even.The footholds were also an early design as well as the hull.Thought about buying some TOBY footholds,but after talking with him,decided to cut and reshape the existing ones.Thanks Toby for your advise.This will be my starting point,redesigning the holds to where they will fit better.As you can tell from the pics,l have already started cutting them back somewhat to be flush with the sides.

 

[G-Body]

Looks like that one was made right around the same time as my superfreak was. The back sides of your hull appear to have a more aggressive rocker at the outer edge, but less aggressive rocker as you move toward the center. My freak is my favorite ski, it`s at home in any riding conditions, does everything better than a superjet, nice and stable being that its full length, but you can still toss it around almost as easily as my WDK Rip. It hurts to see you cut the sides though, I really like the swoopy sides on mine. Gives the ski more character. I almost want to splash my hull just so I can get another, everyone in my family always wants to ride the freak if we go out riding.

 

[Sanoman]

Looks like that one was made right around the same time as my superfreak was. The back sides of your hull appear to have a more aggressive rocker at the outer edge, but less aggressive rocker as you move toward the center. My freak is my favorite ski, it`s at home in any riding conditions, does everything better than a superjet, nice and stable being that its full length, but you can still toss it around almost as easily as my WDK Rip. It hurts to see you cut the sides though, I really like the swoopy sides on mine. Gives the ski more character. I almost want to splash my hull just so I can get another, everyone in my family always wants to ride the freak if we go out riding.

Me filling in the swoops on the sides is more of a necessity for getting back on in deep water.Yours looks awesome!

 

[Sanoman]

Some progress today.Cut all the glass that l needed for the idea l had in my head.The front of the footholds somewhat protrude into the tray and the shape was all wrong.The top of the holds didn't come out far enough to get my feet in,so l cut the front of the hold flush with the sides and then cut off part of the hold in order to build up a wider hold with pink foam.l also cut the top of the gunwales somewhat to try and get it even looking.Got some Great Stuff just to have something to form to later in the process.Great Stuff is perfect being able to come back after it dries,sand and shape.Then l can go over it with thickened epoxy and then wrap it with fiberglass.
As you can look at the pics,l have got an initial shape with the pink foam.l'll glue that down next and then start sanding.
Long ways to go..

 

[Sanoman]

Not much progress this week,but planning on spending some quality time in the shop this weekend.I cut down the foam for the sides a little more and fastened them down with the great stuff.Also added some around the revised footholds.Something interesting that l never would have thought about,is the way the great stuff glues down the pieces l made from the foam.That chit locked the parts down solid.NO,l would not count on it as the only thing securing down a part.Plan on going over all of it with thickened epoxy and then glassing over.One of my concerns is getting the edge straight where the sides will meet the turf.Going to have to make a new lip and sand down accordingly.
So plan is to rough the shape for both sides, form up the footholds to their final look this weekend.lf l can get all that done,then I'll start removing the engine,pump and handlepole..

 

[Sanoman]

Haven't done much since my last post.Work has been unusually busy for this time of year for me.Which l have no complaints,but it is when l have time to build skis.
Anyways,l mixed up a little thickened epoxy,enough to do one gunwale.I have some sanding to do,but that is the shape l want for the revised hold.And l also want to cut the gunwale down just a little more towards the rear where l have it masked off.Long ways to go but happy so far.I will wrap all of my work with some 5 oz. glass twill and then a piece of carbon (got some 11 oz) over if it.Should be strong enough.
Been raining so much that l haven't been able to get outside and sand the tray and sides.But the sun has popped out today!

 

[Sanoman]

Just got a lot of grinding and shaping done Sunday afternoon.Close to the shape l wanted.Now more thickened epoxy on the right side and cap the tops of the ends.
Once l get the sides where l like them, l need to make the step where the turf edge meets the glass straight and get rid of the curve.
Went to Northern tool and bought a better small belt sander than the harbor freight one l've had for a while.The problem the HF one had was the belt kept slipping off with the slightest amount of pressure.The belt sanders are great in tight places,like under the tops of the holds.
I have some time today to mix a batch of epoxy up and cover some of the areas described.Still need to sand the rest of the tray out.

 

[Sanoman]

Got some mudding done on the gunwales yesterday .Basicly done,just gonna wrap with some carbon after a suck ton of sanding.You could not have got me to believe the holds were going to be solid after a coating of thickened epoxy.
Once l get the carbon wrapped around the areas that l changed,the rest will be done with padding and turf.

Not as low as you imagined @ScottS !

 

[ScottS]

Looks like a lot of work, but you will turn it into a work of art. As far as being low, looks like it will work as long as you don’t do riser bars. Us old guys need all the help we can get, getting back on that ski in rough surf. Elbows are the trick.

 

[Sanoman]

Looks like a lot of work, but you will turn it into a work of art. As far as being low, looks like it will work as long as you don’t do riser bars. Us old guys need all the help we can get, getting back on that ski in rough surf. Elbows are the trick.

The only thing l ever found that was good about riser bars,were they were good if you need it a little more length on a handlepole.Not so interested in a work of art Scott,just customized to my needs.

 

[Sanoman]

Got to thinking that l may want to do a rail mod.Not widen them,just where they turndown a little longer.
Opinions??

Then again l don't want to turn this into a "dance floor" project!!

JK @Req

 

[Req]

I would widen them, I would also make the toe hold bigger, widen the tray, and install helium instead of foam for the extra kick in the flips. Dont sell you ski short, do it right! /s

 

[Sanoman]

I know you're kidding Req,cause this "old freak ski" is not getting a lot done to it.lts a dedicated surf ski and will get used and abused.
Probably doesn't look like l did much this weekend (l didn't ). But spent an hour grinding down all the areas affected to prepare for a top coat.l also messed up and got the left foothold too thick,so l had to grind it back down and redo.Added a thin coat of thickened epoxy over every thing.Just need to wrap with cloth now (seems like l said that before) but need to sand a few high spots before.Filled all the holes in the dash to have a clean start.
Maybe l can move on to stripping everything off it inside and out later in the week.

 

[Sanoman]

Started stripping her out tonight.Gets new paint and turfLots of small issues to take care of,but the old freak has done well for 4 years.l haven't much to it in that time.
Took the pump out,it's going to be rebuilt.Looks like the prop needs some love too.And getting rid of the wsm wear ring.Look at the difference between it and the Solas stator.As you can see the oem pump shoe is missing a piece,(wondering if that's where the prop got roughed up) that will get an aluminum one.The midshaft is getting a rebuild too.Just a little bit of rust on it.
Got the pole off and pulled the steering and throttle cables out.l still need to get the hardware off around the pole bracket area and glass up the two extra large holes.The pole surround needs some love too.Has some spider web cracks in it.l also want to redo the cut areas.Make those cleaner.The pole will get sanded down and painted.
I got all the strap hooks out of the engine bay.Just need to get the engine out now.

The only thing l can't decide on is molding in the tubbies or not.Probaby don't have enough time to do them right cause in a month it will be ride time.Just going to smooth them out,paint and reinstall.

 

[McDog]

Why is it a nightmare?

 

[Big Kahuna]

Why is it a nightmare?

Shaking head..............

 

[Sanoman]

Why is it a nightmare?

Shaking head..............

All the good thread titles were already taken.
It startred as a simple project but it's becoming more work as l dig deeper.Henceforth,my little nightmare

Got home from work today and finished stripping it out.Took the tubbies off (thankful l used silicone instead of 5200!) and got the turf off the rails.Took the pump shoe out in several pieces.Whenever it was installed,it was molded it into the pump tunnel.Little bit of a struggle.l also got most of the inserts out from the engine bay.I can grind the rest of the epoxy out tomorrow that was left around them. The battery tray at the bulkhead had one insert missing,as well as the tray beside the gas tank.l may just cut the rest of them off at the bulkhead.
Handlepole is stripped and needs some divots filled and the hood Is ready for prep and paint.Both of those pieces are carbon,while the hull is glass.
Body needs a lot of small places fixed on it too.

 

[Sanoman]

Spent yesterday afternoon grinding the inside where some turf was glued down,as well as what was left of the epoxy around the inserts,also the rails from what turf was left on them and the gunwales.l'm not happy with the way they (gunwales) are shaped.Got my belt sander out and straitened the tops out,but they still have some high and low spots. Just used thickened epoxy with Cabisil to form them.So l placed an order to us composite for an epoxy kit and fairing compound.That will make the sanding a lot easier.
The front and side footholds have some small cracks in them,so l'm gonna wrap them with some cloth and reset new inserts today.Pics later..

 

[McDog]

As an afterthought you could have just used black pad to straighten the gun whales. Hindsight from a recliner is always a great perspective, though

 

[Sanoman]

As promised,pics