Superjet - Project RS *Build Complete (for now)*

[Mud-Nut]

I'm still alive!! And I even have an update for you guys. It's not a big update, but at least it proves I haven't totally forgotten about this project.

Basically, I spent an evening cutting up the rear section and fitting the ride plate.

Fits pretty good!

Also stood the ski straight up to reinforce the nose area some more.

This weekend and following week I'll be finishing up some house stuff, then I have one last trip to the sand dunes planned... But after that, I'll have more time to focus on the Superjet. Stay tuned!

 

[Vince-Netherlands]

Very nice build, with topics like these i can't wait to finish mine as well.
But i recently bought a house and thats consuming most of my time and work at the moment...
But the ski and bills have to be paid somehow.

Good luck with the build, looking good !

 

[Mud-Nut]

Very nice build, with topics like these i can't wait to finish mine as well.
But i recently bought a house and thats consuming most of my time and work at the moment...
But the ski and bills have to be paid somehow.

Good luck with the build, looking good !

Thank you!
I completely understand the house thing... That's part of the cause of this project going so slowly.

 

[plaidward]

Nice, matches well, so you were able to get one turn out how you wanted?

 

[Mud-Nut]

Nice, matches well, so you were able to get one turn out how you wanted?

The one I used was the original ride plate I made with the carbon/kevlar hybrid. It was the best one of 3, it really just needed a few repairs on the inside. I experimented with vinyl ester and straight carbon for the following two ride plates, and they didn't go so well.

 

[Gus13Letter]

WOW!! That is some insane nice work! Cant wait to see final outcome.

 

[Mud-Nut]

Cant wait to see final outcome.

You and me both!

 

[Mud-Nut]

Progress is much slower than I would like it to be, but at least I'm moving forward! I have a baby on the way (end of April 2016), so that's somewhat of a project deadline!

Anyway, I covered the inside of the ride plate in duct tape and taped it into position.

Here's what it looked like inside the tray.

Used cabosil/resin mix to fill all the gaps and make all the transitions smooth.

As an engineer, I tend to overthink things way too much... So, of course, I came up with an overly complex layup. Started with some s-glass, and then there's a combo of roving, 1208, and chop in there.

But I ran out of resin.... So ordered some more and continued with the complex layup (mostly 1708).

Finally, the exciting part! Started yanking the tape....

Way too much cabosil/resin mix got forced in and pushed the tape back, which is okay. I'll just sand it down. But overall, my plan worked!

The ride plate took a bit of hammering and prying to get it to release, but that's what I expected.

And here's how it turned out (not a great pic, I'll flip the hull and get better pics).

 

[Nate_D]

I like your approach a lot better than how I did mine. Keep up the good work!


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[airport joe]

Congrats on the kid Serge, ski is looking really good also!!!

 

[Mud-Nut]

Thanks guys!

The next step is to prep the entire lower hull... Which requires some fairing compound, maybe a bit of glass, and a lot of sanding! I was enjoying the unusual 70 degree weather outside today while sanding, and decided to snap a few better pictures for you guys.

Remember, my hull was already chopped 7 inches (a little too much, hence why I made the new ride plate longer). With that said, here's a shot of the old ride plate (covered in bondo and paint from when I made the ride plate mold), compared to the new ride plate.

 

[Mud-Nut]

Cut down the gunwales, decided to go through the tray support wall, which makes for a little more work, but I don't like the look of the "humps" in the gunwales, as most people do.

Received my stainless hardware from McMaster Carr for mounting the ride plate.

This was the tricky part.... Drilling holes in my ride plate and hull (really not a big deal, but it seems so scary at the time).

After drilling, I had to work the inside a bit to get it nice and flat.

Carbosil/resin mix to get everything into place, with rubber caps (also from McMaster Carr) to prevent water from getting into the tray.

Time to work on the exhaust. First I cleaned up the waterbox and test fit it.

Exhaust material.

Got to test out the new welder.

I also built a little support in the middle of the tube, just to relieve some of the stress and prevent cracking where the edges of the tube meet the hull (probably overkill). Nothing is bonded in yet, I have more stuff to do before pulling out the 5200.

Slash cut out the back. YAY!!! No more front exhaust on this ski!

And lastly, here's just a random overall shot.... I CAN'T WAIT FOR SUMMER! But I have to keep moving forward on this ski, otherwise it'll be another summer of riding the wife's SN (and if anyone is keeping track, I'm not progressing very quickly).

 

[plaidward]

Nice man, getting back at it!

 

[Mark44]

Cut down the gunwales, decided to go through the tray support wall, which makes for a little more work, but I don't like the look of the "humps" in the gunwales, as most people do.

Received my stainless hardware from McMaster Carr for mounting the ride plate.

This was the tricky part.... Drilling holes in my ride plate and hull (really not a big deal, but it seems so scary at the time).

After drilling, I had to work the inside a bit to get it nice and flat.

Carbosil/resin mix to get everything into place, with rubber caps (also from McMaster Carr) to prevent water from getting into the tray.

Time to work on the exhaust. First I cleaned up the waterbox and test fit it.

Exhaust material.

Got to test out the new welder.

I also built a little support in the middle of the tube, just to relieve some of the stress and prevent cracking where the edges of the tube meet the hull (probably overkill). Nothing is bonded in yet, I have more stuff to do before pulling out the 5200.

Slash cut out the back. YAY!!! No more front exhaust on this ski!

And lastly, here's just a random overall shot.... I CAN'T WAIT FOR SUMMER! But I have to keep moving forward on this ski, otherwise it'll be another summer of riding the wife's SN (and if anyone is keeping track, I'm not progressing very quickly).

Love the look of the pipe however it looks like it could really hurt ya.

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[Mark44]

Love the look of the pipe however it looks like it could really hurt ya.

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On the other pic

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[sneds]

Lookin good!

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[mike b]

Man this ski is looking wicked! Great work. Can't wait to see the finished project!!!

 

[air blair]

Great job duder. You got your time into that baby. Gonna be a fun setup there.


Air blair cell

 

[Mud-Nut]

Thanks everyone! I've been working away on the ski some more, just give me a few days to compile the pics and post an update.

Nice man, getting back at it!

Ya dude, summer is just around the corner. You should do the same!

Love the look of the pipe however it looks like it could really hurt ya.

Thanks, and I appreciate the concern. I'm not too worried about it because the pump/nozzle stick out much more than exhaust. The ride plate also sticks out, and right now I'm thinking of extending the tray as well. I'll take a look at it once everything is assembled and see if it's an actual concern or not. The exhaust can be cut back some more if needed.

Great job duder. You got your time into that baby. Gonna be a fun setup there.

Thanks! I don't think I live too far from you, and I can definitely learn a thing or two in your shop! You should invite me over next time you're laying-up a hull, haha!

 

[Mud-Nut]

Update time!

I was fairly confident in the welds for the exhaust, but I wanted to be 100% sure that it wouldn't leak. So I coated the welds with exhaust sealer and then painted over it (the paint was to prevent any corrosion from contaminants during prep/welding).

I also got the scupper setup ready for installation... McMaster Carr sump pump 1-way valve, 2" ID tube, and a 22.5 degree bend.

It's never easy to drill giant holes in the hull.

Drain's installed.

There's not much room between the tray and pump. I didn't want to run a long cable that could bounce around and whatnot, and I wanted the cable gripper closer to the trim lever. So I came up with this....

Installed everything with 5200. Stuff works awesome, but dries really slow.

Fiberglassed over the trim tube and started fitting as much foam as I could.

I took notes before tearing into this project... Basically, I didn't mind the footholds, but I wanted to make some tweaks to their layout (wider, lower, tilted forward slightly, and turned a bit for a straighter foot). Left is new, right is old.

Once I got the footholds both exactly where I wanted them, I glued them in place and then kept stuffing foam in there.

Picked up an aluminum pump shoe to replace my beat up OEM one.

A bit more gunwhale trimming.

Expanding foam is fun!

Glassed in the engine bay openings (holes from trimming down the gunwhales).

Took advantage of the gorgeous January weather and worked outside (sanding down the foam).