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  1. #1
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    91 kawasaki 440/550 reed custom build part 2

    last winter i started this ski build and didnt quite finish. the ski when i bought it was a stock looking 91 440 that a 550 reed engine was swapped in before me... engine was stock bore with weisco pistons and a rogo head.. the last build included a new pipe, impeller, shredmaster grate/plate combo, widening tray and footholds and decal removal.. here is a link to part 1 build: http://www.pwctoday.com/showthread.php?t=331343

    i had a blast with the ski over the summer and after some impeller changes, the ski is very squirrely at high speed..the ski doesnt turn very well either which i discovered it had the stock steering system in place.. the changes i hope to make are more power with the ported cylinder.. i will be documenting and starting a new thread in the vintage ski section about the engine, carbs and porting...

    2012 build list includes:

    deeper strakes, trued hull- should make ski track better and carve deeper
    650sx quick turn setup with 0 degree bars. this setup gets you closer to the nose
    driveshaft fill- i loved the 16pitch prop i ran but had slight cavitation on acceleration im hoping the fill will solve this
    new turf
    top end rebuild with cylinder porting
    dual 38sbns
    hopefully new paint
    dual cooling- one line for engine and one line for pipe for better water control
    bulkhead brace- bought it last year, never installed it

    i will be posting pics very soon.. ive already done the driveshaft fill, dual cooling, and strake mod.. just waiting on the glass to get here because im putting a few layers on the entire bottom of the ski then pics will start..
    Last edited by fastgtfairlane; 04-18-2012 at 10:53 AM.
    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
    Top Dog 440Splash's Avatar
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    Re: 91 kawasaki 440/550 reed custom build part 2

    Subscribed.
    2000 SeaDoo RX Millenium Edition
    1990 JS440 (Original Owner) PJS Ski (Peek at photo album)
    1989 JS550 "Haulin' Harry G's" Westcoast Ski (Peek at photo album)
    1986 JS550 (Daughter's Ski) Almost completely stock - for right now


    2011 GREAT LAKES WATERCROSS TOUR - Vintage 550 1st Overall
    2013 GREAT LAKES WATERCROSS TOUR - Novice Ski Lites 3rd Overall (KAW SXR #147)
    Thanks to SPONSOR S.Hyke Performace Racing Products

  3. #3
    PWCToday Guru pepperson4's Avatar
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    Re: 91 kawasaki 440/550 reed custom build part 2

    subscribed
    Truly, truly, I say to you, whoever hears my word and believes him who sent me has eternal life. He does not come into judgment, but has passed from death to life.John 5:24
    Jet skiing for Jesus

  4. #4
    Top Dog N2 H20's Avatar
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    Re: 91 kawasaki 440/550 reed custom build part 2

    You gonna be done for the Carolina Beach Freeride? I'm going to be cutting it ridiculously close if I get done.

  5. #5
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 91 kawasaki 440/550 reed custom build part 2

    the only thing that would keep me from being done is finances.. i picked up a set of 38sbns that will need lots of parts.. im not gonna press the turf or paint before the free ride.. the engine should be good if it checks out.. im gonna pick up some engine tools tomorrow and take the cylinder off.. i purchased another cylinder to use but it looks like its gonna need to be bored so im gonna stick with the one that was on it.... i took the intake and exhaust manifolds off for a quick inspection and it looks good so far.. well see when i measure the cylinder... the hull will be done after a few layers of glass, sanding and im gonna paint the bottom..

    i bought a dremel and some bits to do the porting and they came in today! im gonna get the flexible extention thing too.. there will be some late nights in my near future haha
    Last edited by fastgtfairlane; 04-19-2012 at 12:35 AM.
    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.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 91 kawasaki 440/550 reed custom build part 2

    Updates! Got the strakes shaped and ready for glass..placed an order few days ago from us composites with 5 yards of 12oz biaxial and i believe 8oz cloth tape for the strakes.. i will put 3 layers of cloth over the deepened strakes followed by 2 layers of 12oz biaxial over the entire bottom of the ski..ski bottom1.jpgski bottom3.jpgstrakes1.jpgstrakes2.jpgstrakes3.jpgstrakes4.jpg
    also completed the driveshaft fill.. to do this mod, measure the inside diameter of the pvc for the driveshaft hole.. i used a sink extension for your home sink and cut to fit.. the filler i used is called fuser 114 by a company called lord.. its a plastic finish adhesive that works with smc.. i picked it up at a carquest body shop supply store.. http://www.lord.com/products-and-sol...roduct.xml/302 kinda pricy but worth it and worked perfectly.. used less than half the tube.. actually did the entire mod in a day..

    apply it in small amounts and let cure which takes about an hr.. continue until filler is built up higher than the rest of the tunnel.. i used 80 grit to sand smooth now its ready for paint...

    strakes5.jpgstrakes6.jpg

    driveshaft1.jpgdriveshaft2.jpg

    to complete the dual cooling mod, i went to harbor freight to get the drill bit to drill through the hull.. they have a cable drill bit with 3/8 bit that is 48 inches long.. perfect! i searched locally for a 3/8 hard copper line or aluminum with no such luck... i ended up using 3/8 od pex line from home depot.. this stuff is very strong according to the plumbing specialist and was very cheap like 3 bucks for 5 foot piece.. just needs to be sealed up which i will do when i finish with the bottom
    Last edited by fastgtfairlane; 04-22-2012 at 01:14 PM.
    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

  7. #7
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 91 kawasaki 440/550 reed custom build part 2

    my order of biaxial and cloth came in today! have a lil more prep work to do to the bottom before i can apply glass.. gonna do that tomorrow should be glassing thursday!
    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: 91 kawasaki 440/550 reed custom build part 2

    glass is getting spread today! pics to come...hoping to finish the bottom by the end of the weekend including 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 fastgtfairlane's Avatar
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    Re: 91 kawasaki 440/550 reed custom build part 2

    updates! Glass is on, 3 layers of 6oz tape which i started with a 3 inch, 4 inch, and 6 inch layer of tape and one large piece of 12oz biaxial on the entire bottom and side of the ski... that biaxial is very thick stuff and it took what seemed forever to wet it all out.. for anyone looking to do any kind of fiberglass work, i highly recommend this tool..http://www.uscomposites.com/fgrollers.html i purchased it when i ordered my fiberglass..i wouldnt have gotten the biaxial to lay down under the bondrail without it.. Now just need to sand and paint!

    bottom glass1.jpgbottom glass2.jpgbottom glass3.jpg
    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

  10. #10
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 91 kawasaki 440/550 reed custom build part 2

    time for updates.. finished painting the bottom of the ski and got it all put back together for the big freeride event at Carolina Beach NC. got to ride for about 15min before my steering cable broke dohhh! took the ski back completely apart and reset the driveshaft alignment and pump only to find the woodruff key sheared! i noticed a funny noise coming from that area while i was running the ski on the hose to flush out the saltwater from the beach... decided to pull the flywheel cover to find the flywheel has lots of play in it.. removed the flywheel to find both the flywheel and crank snout gouged to hell... soo i get to rebuild the engine sooner than i thought... this is my first time building a two stoke engine... since i have the engine apart i decided to do a lil porting... should be finishing the engine up by friday to ride saturday... im going to do a engine build thread seperately and go into more detail on what and how i did the porting... preview pics here
    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

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