Custom/Hybrid Superfreak Re-Build!

[mightymighty2stroke]

This is my fourth season with my RN SJ, and I'd been really thinking of changing it up. Motor and handling wise, it was already a peppy 701 (pipe, reeds, head, prop, MSD, etc) that handled well (grate, plate, holds, shorter pole) but I wanted more. Also, the ski felt on the heavy side to me, and that was backed up by all of the people who helped me slog it around at wave daze...seriously everyone was like, "this is the heaviest SJ I've ever handled". Out of curiosity I weighed it on my buddy's scale the other day (one of the scales for a race car). 355lbs with 4 gallons! If you figure a gallon of gas weighs 6.1 lbs and subtract that out, we're still talking about a 330lb SJ...I can only assume the foam is wet also.

By the time I added up all the money I wanted to spend improving the SJ, and more importantly the time, which I'm super short on lately...I started thinking of just getting an AM hull instead as the cost of that vs. what I was going to spend on the SJ was very close. I've ridden a few different ones at free rides, but I wasn't dead set on any particular one - any of them seemed like a vast improvement. Only thing I knew for sure is that I didn't want one of the super short ones - I'm not tall at all and they seem to really put me in an awkward position. I also didn't want to blow a ton of money, or order one (hate waiting).

One day at work while at lunch I just happened to hop on the X, which is something I never do (I just put my phone down for lunch bc I need quiet time LOL). I was looking at hulls for sale and found a -2 glass superfreak had popped up "local" to me. Lo and behold it was in great shape and in my price range also. I figured it was a sign, time to move on from the SJ! I liked the SF I rode a couple years ago, and it's very hard to find people who have negative things to say about them. I couldn't PM the seller fast enough.

I gotta give a big high five to the seller...he was awesome - a complete 180 from the douche I got my SJ from. He told me absolutely everything about it, every little scratch, nick, etc. Sent me a million pics without being asked. Offered to fix the fuel tank mounts. Just a super nice guy, I would buy anything from him! He was even kind enough to drive an hour out of his way to meet me (I was going to GA from NC), and make a list of do's and don'ts for the build. It doesn't get any better than that folks - thanks a ton, Gregg!!

I didn't waste any time when I got home. I stripped down my SJ and took a lot of comparison pics. I always see pics of finished skis but never pics of an AM hull next to say, an SJ, so here you go for future reference. Sorry about the dog, he's all up in my grill constantly so he's in most of the pics.

SJ before teardown (it's a mess, I know!)

One hour later...

A few side by sides. Both noses are pushed up against the door so they are even.

Aside from swapping over everything from my SJ, I'm also adding the thrust EZ pull trim - can't wait to try that out! I hope to have this wrapped up by next weekend. I'm sending a couple things out for powdercoat...need to order a new midshaft bearing (saw that the seal's busted on mine and it doesn't rotate smoothly either!) and hopefully the rest of the small things I ordered will be in on Monday or Tuesday.

I do have one question for the X. Should I leave my pole alone, or powdercoat it black? Here it is just laying on it -

 

[JT_Freeride]

Congrats on the SF, I really like the color. If you don't mind paying for the powder coating I would do it

 

[ProSouth]

powder coat it. congrats on the freak. This ski is awesome. i got to ride it a couple times. It won't disappoint.

 

[Sanoman]

Are ya done yet? lol


Should be an awesome ski,you will be spoiled.

 

[McDog]

Gonna miss that ski. Enjoy.

 

[Pablo]

I appreciate the good words for being upfront on the sale. I didn't want you to be caught off guard by any findings. Buying a used hull, engine, or ignition is a big leap of faith in the seller. I hope the build goes smooth. Don't forget the check and double check ur bolt depths and cut that bottom midshaft bolt down for sure...at least three threads. Thread sealant is ur friend too.
The ski looks good in ur garage...Nice garage too! Can't wait for the finished build and first ride report.

We should have a positive feedback section for stand-up (pun not intended) buyers as well. It's a pain for sellers when the buyers are difficult to deal with or want to change agreed upon terms when its time to exchange funds. Kelley has been a breeze to work with and stay in contact with. Have fun. Once u get Freaky its hard to ride anything else and not compare the ride. I dare say a Freak is benchmark for pretty much all other hull builders.

 

[mightymighty2stroke]

The ski looks good in ur garage...Nice garage too! Can't wait for the finished build and first ride report.

Thanks - it's actually my work. We do late model chevy performance (installs, parts, dyno tuning). It cost me a pretty penny to have the floors epoxied but it was totally worth it. They are so easy to keep clean and they look amazing - all of my customers comment on it! Plus, the light gray makes it really easy to find bolts and small parts that hit the floor. I swear that it helps reflect the shop lighting also and makes it brighter.

I didn't get very far today at all, I spent way too much time dicking around trying to remove the engine & midshaft couplers (I've had Cold Fusion ones sitting in a box for two years now). They were not coming off for anything. I tried a torch (don't worry my midshaft bearings are shot anyway - I'm replacing), letting it soak in PB blaster, a pry bar almost as long as I am, etc. nothing. And now I'm annoyed because the socket that you tighten the prop on with is now stuck (I had that on there in a vise, then slipped the midshaft over the driveshaft to keep it still while breaking loose since the vise would not hold the shaft itself without it turning). Same thing with the engine side. I had it chained to the four post lift so it couldn't move, nothing, it just sent my flywheel holding tool skidding across the floor. The juice is not worth the squeeze - I will wait until I need a new crank for some reason (hopefully not soon!). Just hate that I wasted so much time on it today. I wanted to stay later but I told my husband I'd go with him to see world war Z so I gotta get cleaned up.

I did however make a bilge bracket...also going to order the stuff to get the battery location back in the stock place - it seems like it would be impossible to change/get to if it were in the corner like it's supposed to be (I like the normal sized PWC batteries not the lightweight little PITA ones). Tomorrow after work my goal is to get everything in and lined up/marked, my trim and the rest of my parts should be coming in Tues/Weds so all the rest should be pretty cut and dry. I'm going to wait to powercoat the pole - just in case I get it installed and decide it needs to be longer/shorter (it's fixed so has to be cut/rewelded).

 

[mightymighty2stroke]

Made a little more progress tonight. Got the pump lined up, midshaft lined up, and engine as well. I was a little surprised how smoothly it went, surely I'm doing something wrong? I'm using my SJ motor mounts and it only took .056" worth of shims on both rear corners. I'm attaching pics with a scale as a straight edge so you guys can check my work. I know it's hard to tell but there are two pics on either side and then one with the scale on the very top.

Also got the blowsion lowered pole bracket mounted up, along with hood straps (are those on right? The last set I made myself and tied into my hood hooks, not sure how the 'commercial' ones are meant to be installed).

The t-nuts will be here tomorrow (to put the battery in the stock location) so those will get glassed in tomorrow night. From there it shouldn't be long at all. I have the engine back out again to spray bomb it. My trim should be here on Friday, fingers crossed. Picking up a rebuild kit for the midshaft housing thurs. Hopefully the rest is easy going so its RTR for the weekend!

 

[SX-R 800 Ripper]

Yeah that's exactly how I put my hood straps on with the blowsion pole bracket

 

[mightymighty2stroke]

Brap!! I started putting it back together Thurs and had it ready late Friday (just had to stop on the way to pick up a marine fuel filter and a 3/8 t for the cooling!) I'm so pleased that the maiden went well, I was nervous about it since this was my first AM (re)build. Everything went together fairly well - the biggest hurdle was making the ride plate fit, and I still don't love the way it is so I'll redo that this winter.

Rebuilt midshaft - it had blown out a rear seal and felt really grindy. Painted it to look pretty since I couldn't get the stock couplers off!

Had to redo the trailer too - got the Seadoo trailer mount that people talked about in the original SF thread

Added mounts to put the battery in the stock RN SJ location. It is important to me that the ski is easy to work on, and I want to run the full size battery as well.

EZ Pull pro trim system from Thrust. Figured I might as well do it while the ski was apart anyway, soooo glad I did.

What do you guys do about your cables/routing them in? I have the stock SJ rubber mount (it has several holes in it for the cables to pass through) and then ran that through the tube that comes with the blowsion bracket. It's not ideal but at least stops some of the water from coming in - let me know what I should do differently. I also went back and added grommets to the hood straps (not in this pic).

Had to further deepen the d-cut in the ride plate to clear the bolt on the bottom of the trim nozzle.

30 degrees of trim, woot woot

I had my Factory pipe & head pipe powdercoated in silver hammertone, I love the way it looks. Plus, unlike the chrome color it comes or black, it doesn't show water marks on it when it dries. I got new hoses as well. Loving the clear fuel lines, makes it so much easier to see which way everything's going, especially since I derped and put the filter on the wrong line - was able to quickly see that on first start up and correct it.

I elected not to run a reserve, I didn't want to hack up the dash to put the SJ on/off/res switch on it. But, after running out of gas because I was not careful :crazy: I'm rethinking this decision :scratchchin:

I also went back to the stock airbox. I never saw a big gain from the K&N's and all they really did anyway was ingest a ton of water. That's a stock SJ tank that I painted (left a strip off so I can see the level).

 

[mightymighty2stroke]

Here's a few more pics of how it ended up. I'm going to have the pole powdercoated black, but I'm not sure if I want to lengthen it yet or not. It was perfect on my superjet, but since the pole is moved 2-3" forward on this, I feel like I have to reach for it (I'm 5'3" with little t-rex arms). I'm going to ride it a few times though before making that call...there's so much to get used to!! I'm head over heels for the ski though, it is everything I wanted and more. I haven't weighed it yet but it rides sooo much lighter and is a lot easier to throw around. The trim is so badass, I wish I had it before.

I think the power it has is excellent also - it's just a 701 still (pipe, head, reeds, lightened FW, ported manis) it may not be a big DASA motor but at 115lbs I have a better power to weight ratio than most of you, lucky me

This is going to be a great summer!!

 

[Pablo]

Turned out great. The engine bay is super sano. Nice job. I had to do the same thing to my ride plate. Don't forget to check those tray drains every 3-4 rides. Did you do the hammer-tone paint job on ur pipe? Rustoleum??? I'm gonna repaint a headpipe soon.

 

[mightymighty2stroke]

Turned out great. The engine bay is super sano. Nice job. I had to do the same thing to my ride plate. Don't forget to check those tray drains every 3-4 rides. Did you do the hammer-tone paint job on ur pipe? Rustoleum??? I'm gonna repaint a headpipe soon.

Thanks! It's actually powdercoated in that hammertone color. PC is the best way to go IMO - very durable and long lasting. I'll keep checking the tray drains. The scupper is crazy (never had one before) I can't believe how fast it takes care of any water in the engine bay.

 

[mightymighty2stroke]

Changed over to a versi plug Max this weekend, glad I did. When I pulled the Epic off, the flap was dry rotted on the back. I feel a bit more secure now. It seems the scupper tube isn't the schedule 40 2" PVC the Versi is meant for, it had a slightly larger ID than a piece of pvc I had sitting around, but I was able to make it work, and it's not leaking. The Versi is securely mounted with four screws into the tube.

 

[MCrider]

Looks stupid clean man I hope to join the am hull army sooner or later.

 

[mightymighty2stroke]

Wellllllllll...after a month of riding, my engine locked up. Weirdest thing, was just riding along and it cut off. Tried to restart, nada. Went to shore, popped hood and tried to start it, I could see the midshaft turning about a quarter inch at a time...that starter was struggling!! I was eventually able to turn the motor over by hand but it kept hanging in one spot. I've had a few great years with that motor, I couldn't be mad after literally beating the crap out of it for so long...my only hitch was that the motor locked up just 20 days before the Lake Erie freeride, which I love going to! Nooooooooooooo!! What ever could I do?!?!

Na na Na na Na na Na na JET MANIAC!!! Na na Na na Na na Na na JET MANIAC!! (btw the 'na na na's' go to the Batman theme song!!) to the rescue. I PM'd him in a fit of desperation, knowing there was absolutely no way I could rely on any local machine shops to turn around the motor in time. I told him about my ridiculous deadline (needed it back by the 16th), and he said no problem. Dude totally delivered...one day early a gorgeous 735cc shows up at my work. Whaaaaaat!! Awesome turnaround time, and soooo helpful every step of the way. He also suggested a Hooker 10/16 to go with the new build (from a skat 12/17) so I threw that on too.

Behold!!

All artistic-like

Routed my cooling lines a bit different. Only thing I still want to do is replace the brass NPT cooling fittings with some black AN fittings, to look extra slick.

Finally on Saturday I had a minute to finish it up at the lake lot (had to pick up a couple things on the way). And on Saturday as it has been every freaking Saturday in NC this year, it was pouring rain. But no s were given, this thing was getting broken in. BTW the umbrella is so water doesn't get in the carbs, not for me.

Broke it in as directed and then let it rip. Feels awesome!! Finally the sun came out on Sun so I took a few more pics of the ski.

Yay for making the free ride with a running ski!! Couldn't have done it without JM's sick turnaround time.

 

[JetManiac]

Ski and build look great! You sure got it back together and in the water quick.

 

[Gski251]

Newbie question. What are the perks behind cutting down the side rails like that? Cornering?

 

[Big Kahuna]

There not cut down, This is a completely different hull than a SJ. Wider Tray, Lower Hood and Pole area............

 

[Big Kahuna]

@Sanoman Is this the same one you have now?