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  1. #1
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    1st ski build major customization

    i bought my 1st ski from this site last april and spent last summer learning to ride it..i had a hell of a summer last year learning to both work on and work on my new ski... it didnt take long for me to figure out how to work on it and how to modify the ski as well..over the winter, i decided to try fiberglassing for the first time and see how creative i can get with this project..

    I decided to widen the tray 3 inches and i wanted footholds as well.. I did 3 inches to not innerfear with the rear exhaust and still be able to install footholds. i have seen several people do this but they didnt install the holds as well. i measured 3/4 of inch from the inside of the gunwale then 1.5 inches more.. cut out the center and removed the foam as well. on the right side, i cut down the center of the inner side of the gunwale so that i could cut the extingisher part out as well...
    Attached Images Attached Images
    91 440; PJS Viper 7000, jetsport exhaust mani, factory full pipe, coffman waterbox,solas 17*, jetco worked 440 pump, ocean pro nozzles. shredmaster ocean rideplate and grate combo, wide tray, footholds, deep strake mod, driveshaft fill,650sx quick turn

    build thread part 1: http://www.pwctoday.com/showthread.php?t=331343
    build thread part 2: http://www.pwctoday.com/showthread.php?t=364872
    build thread part 3: http://www.pwctoday.com/showthread.php?t=396154

  2. #2
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 1st ski build major customization

    a friend gave me some holds he had in his superjet for free!..i just had to clean up the glasswork on them and they were good to go.. I taped the gunwales back up to fit the holds in..once they fit snug, i used the epoxy glue in a caulk tube i got from west systems to glue in the holds and i also riveted them in..

    Since i cut out most of the foam that was in the ski, i needed to refoam the bunks..the easiest way to do so was to use this foam in a can and hold the bunks together and get the foam inbetween them..once filled to the desired level i taped them together to hold everything together...once that dried, i used the same glue for the holds to fill the gap where i cut the bunks apart...once the foam and epoxy dried, the bunks felt nice and solid....to get the angle right on the right side where the extingisher was, some built up foam that could be cut down and sanded to get the desired shape..when i cut the bunks apart, i cut into the bulkhead by accident..i ended up using the foam again to fill in the holes so i had something solid to glass up..the foam worked perfect and highly recommend it again...
    Attached Images Attached Images
    91 440; PJS Viper 7000, jetsport exhaust mani, factory full pipe, coffman waterbox,solas 17*, jetco worked 440 pump, ocean pro nozzles. shredmaster ocean rideplate and grate combo, wide tray, footholds, deep strake mod, driveshaft fill,650sx quick turn

    build thread part 1: http://www.pwctoday.com/showthread.php?t=331343
    build thread part 2: http://www.pwctoday.com/showthread.php?t=364872
    build thread part 3: http://www.pwctoday.com/showthread.php?t=396154

  3. #3
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 1st ski build major customization

    the foam is really cool because you can cut and sand it to shape anything you want...more pics of prepping and fiberglass..the red stuff is some fairing filler from west systems that you mix with the resin and it is designed to level areas out and is really easy to sand..i used that 1st to get everything smooth to eliminate any air bubbles in the fiberglass...i used 4 layers total and gradually made each layer larger...the 4th layer i wrapped from the outside of the gunwales to almost center of the tray to make everything smooth..
    Attached Images Attached Images
    91 440; PJS Viper 7000, jetsport exhaust mani, factory full pipe, coffman waterbox,solas 17*, jetco worked 440 pump, ocean pro nozzles. shredmaster ocean rideplate and grate combo, wide tray, footholds, deep strake mod, driveshaft fill,650sx quick turn

    build thread part 1: http://www.pwctoday.com/showthread.php?t=331343
    build thread part 2: http://www.pwctoday.com/showthread.php?t=364872
    build thread part 3: http://www.pwctoday.com/showthread.php?t=396154

  4. #4
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 1st ski build major customization

    i still have to sand the tray one more time and it will be complete..i also scrubbed and degreased the engine compartment..part of my plan was to reinforce the bondline area on the sides as i plan to take this ski to the ocean and it is primarily used for wave jumping.. the foam i used to seal the holes i made was sanded and cut down to glass over...i was concerned the entire time with this part and wanting to make sure it was solid once it was done.. i used some adhesive filler on this and the bondline to fill in any low ares and it dries really hard and is used for structural bonding according to west systems..a quick layer of that and 4 layers of cloth and the bulkhead felt really solid..on the bondline i used a layer of mat which is really thick on top of the adhesive filler then a layer of cloth to give it a smooth finish...the bulkhead turned out better than expected.. i measured and recorded everything so when i cut the cloth it lined up perfect...
    Attached Images Attached Images
    91 440; PJS Viper 7000, jetsport exhaust mani, factory full pipe, coffman waterbox,solas 17*, jetco worked 440 pump, ocean pro nozzles. shredmaster ocean rideplate and grate combo, wide tray, footholds, deep strake mod, driveshaft fill,650sx quick turn

    build thread part 1: http://www.pwctoday.com/showthread.php?t=331343
    build thread part 2: http://www.pwctoday.com/showthread.php?t=364872
    build thread part 3: http://www.pwctoday.com/showthread.php?t=396154

  5. #5
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 1st ski build major customization

    got the hull flipped over so i can go through the bottom of the hull..going to fill any super low areas and true the hull...a 3ft section of 4 inch pvc and a 2inch section of pvc and i will wrap 100grit paper around it to remove any low areas...it will sharpen the strakes some to make the hull track and handle better..should really make a difference in how stable the ski is too....
    91 440; PJS Viper 7000, jetsport exhaust mani, factory full pipe, coffman waterbox,solas 17*, jetco worked 440 pump, ocean pro nozzles. shredmaster ocean rideplate and grate combo, wide tray, footholds, deep strake mod, driveshaft fill,650sx quick turn

    build thread part 1: http://www.pwctoday.com/showthread.php?t=331343
    build thread part 2: http://www.pwctoday.com/showthread.php?t=364872
    build thread part 3: http://www.pwctoday.com/showthread.php?t=396154

  6. #6
    PWCToday Guru Escobar's Avatar
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    Re: 1st ski build major customization

    nice work so far..lookin good.
    1988 Kawasaki X2
    1989 kawasaki 650sx '97 750 big pin conversion
    1991 Kawasaki 550SX '95 750ss conversion
    1998 Seadoo XP Limited --FOR SALE

  7. #7
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 1st ski build major customization

    thanks! where in NC are you? Im hoping to be finished in 2 weeks..I am debating on painting everything because im just ready to ride!
    91 440; PJS Viper 7000, jetsport exhaust mani, factory full pipe, coffman waterbox,solas 17*, jetco worked 440 pump, ocean pro nozzles. shredmaster ocean rideplate and grate combo, wide tray, footholds, deep strake mod, driveshaft fill,650sx quick turn

    build thread part 1: http://www.pwctoday.com/showthread.php?t=331343
    build thread part 2: http://www.pwctoday.com/showthread.php?t=364872
    build thread part 3: http://www.pwctoday.com/showthread.php?t=396154

  8. #8
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 1st ski build major customization

    i have not been able to work on the ski...ive been sick and out from work all week due to massive headaches, mixed with dizziness spells, some nausea and no balance..the doctor said i could have virtago...i have an mri tomorrow...hoping to be back on the ski by weds...i did recieve some new parts one being a new pipe! I also ordered some hydroturf, carb rebuild kit, flow control valve and a bilge setup..still debating on what to do with paint..something quick and inexpensive..i just want it to last this season so i can ride and i will paint it better in the off season.. any suggestions on paint??
    91 440; PJS Viper 7000, jetsport exhaust mani, factory full pipe, coffman waterbox,solas 17*, jetco worked 440 pump, ocean pro nozzles. shredmaster ocean rideplate and grate combo, wide tray, footholds, deep strake mod, driveshaft fill,650sx quick turn

    build thread part 1: http://www.pwctoday.com/showthread.php?t=331343
    build thread part 2: http://www.pwctoday.com/showthread.php?t=364872
    build thread part 3: http://www.pwctoday.com/showthread.php?t=396154

  9. #9
    PWCToday.com Is My Home Away From Home monster 550's Avatar
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    Re: 1st ski build major customization

    It's looking nice man. For a cheap and quick paint job just go with the rattle can ratrod flat color beat up look.

  10. #10
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 1st ski build major customization

    thanks! i was gonna try and true the hull and still may im just gonna put the ski back together and go ride, then maybe true the hull so i can see the difference...the main thing is just making sure to get a good epoxy primer that will actually adhere to the smc hull...
    91 440; PJS Viper 7000, jetsport exhaust mani, factory full pipe, coffman waterbox,solas 17*, jetco worked 440 pump, ocean pro nozzles. shredmaster ocean rideplate and grate combo, wide tray, footholds, deep strake mod, driveshaft fill,650sx quick turn

    build thread part 1: http://www.pwctoday.com/showthread.php?t=331343
    build thread part 2: http://www.pwctoday.com/showthread.php?t=364872
    build thread part 3: http://www.pwctoday.com/showthread.php?t=396154

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