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  1. #1
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Apr 2010
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    charlotte,nc
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    440/550 custom build part III

    Leaving off build part II, the ski is one of the most, if not the most fun 550s ive gotten the chance to ride.. handles great, has good power, just needs a little more.. Some of this build will include more reinforcements, most will be handling upgrades, and im stoked about finally getting a paint job on this boat!

    This past fall, i lost a piston on the pjs cylinder so I switched top ends to the kawi reed cylinder i had with new pistons and a port job.. still running the dual sbns. I plan to rebuild the PJS cylinder and get it back on.. the kawi cylinder has good power as well, just has low compression from the port job and no cylinder decking..

    This build will include:

    -Fresh paint and black diamond turf
    -Going to mold my own tubbies
    -Nose reinforcment
    -since I have a westcoast tank, im going to cut out the stock fuel inlet and smooth it over
    -shorten the bottom by 2 inches
    -shave the bond rail on the back
    -reshape the back of the gunwales, just for looks
    -bulkhead brace
    this should finalize everything for this boat.. Been doing some research on tubbies and have seen some examples on people molding their own.. dont really wanna pay 250-300 bucks for a set when i can fab my own for the cost of resin.. even picked up some construction rigid foam from a jobsite Im working at for free! Got to ride some friends superjet that added tubbies and after riding it, I knew i needed some on mine.. the tubbies keep the ski from rolling over when deep turning. this boat sees bouys occasionally, mild freestyle and surf as well so im gonna mount them about `1/2 off the bottom of the ski so i can still have top speed stability.. if they are too low, you can experience chine walk..

    Chopping 2 inches off of the rail caps will give less turning resistance and will also allow more nozzle throw.. still keeping the same long ride plate so im hoping it doesnt get nose high on me..

    paint will be a mix of white, blue and like a light milky bluegreen with black turf.. the bluegreen color is really hard to describe haha but i have a sweatshirt with the exact colors and when complete i think it will be very different...

    already started on the tubbies and have completely tore the ski down.. pics to come
    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 Rompn's Avatar
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    Aug 2004
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    La Crescenta, CA
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    35
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    Re: 440/550 custom build part III

    Subscribed, doing similar mods on my surf 550 build except I'm also rockering the nose which will take about 3 1/2" off the front. Haven't decided about taking anymore off of the rear caps.







    Patrick Goldsworthy
    Region 1 / Vintage Ski / #28

    Chris "Fish" Fischetti & Victor "The Slasher" Sheldon

  3. #3
    I dream skis kupcak3's Avatar
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    Apr 2010
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    OBX, NC
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    29
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    638

    Re: 440/550 custom build part III

    Subscribed!!!! What are you intentions or meaning by 'shortening the bottom 2 inches'?
    pewpew lazers

    89' 550/650 Conversion--Fresh Motor, Stock pipe mod, 44snb, mariner 550 waterbox, OP finned ride plate, 19* Mako Impeller repitched by Impros, rebuilt 550 pump.

    96' Wave Venture


  4. #4
    Top Dog Rompn's Avatar
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    Re: 440/550 custom build part III

    Quote Originally Posted by kupcak3 View Post
    Subscribed!!!! What are you intentions or meaning by 'shortening the bottom 2 inches'?
    He means cutting two inches off of the extensions on the bottom of the hull. The steering nozzle thrust can hit the sides of the extensions when fully turned so when you cut off roughly two inches off them, the nozzle has more throw because it can turn more. I may be doing something similar but since I already have 3 1/2" off the front, another two off the rear may be too short of a hull. I may do a notch type of deal instead.
    Patrick Goldsworthy
    Region 1 / Vintage Ski / #28

    Chris "Fish" Fischetti & Victor "The Slasher" Sheldon

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

    chopping off the on the bottom will allow the ski to turn quicker because of less drag.. im keeping the same rideplate for now, its pretty long so im hoping it wont ride too nose up.. got the tubbies shaped.. resin and cloth are coming this week.. im gonna use some spray adhesive and glue the tubbies to the side of the hull and glass over them.. i have enough foam left to hopefully make a front foot hold.. im gonna also add some foam to the rear of the bottom where the hull caps were and it will have a taper up towards the back of the tray...

    making the tubbies took A LOT of time to get right and to match.. probably 20 hours or so.. but for much less cost and some time i was able to make my own... i got to ride a friends rn who recently put a front foothold, cut off the back as i did and added tubbies.. all i can say is wow what a huuge difference!! im hoping i have them high enough that i wont get any chine walk..

    1365980213929.jpg1365996691045.jpg1365996696215.jpg1365996706465.jpg1365996712344.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

  6. #6
    PWCToday Regular 1978js440's Avatar
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    Oct 2008
    Location
    Goleta Calif
    Posts
    65

    Re: 440/550 custom build part III

    Fastgtfairlane, I'm new to all these hull mods I see on this site. What are you doing to the nose.....what is this mod going to do for you?

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

    thats not me doing any real work to the nose.. i cut out the stock fuel inlet area so i can get my hands inside the nose to reinforce it to make it stronger, im gonna make the nose area smooth.. the other guy that cut the nose off is making it a "rocker nose" for surf.. it will keep the nose up when going down the face a bigger waves so that the ski doesnt nose dive..
    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 Regular 1978js440's Avatar
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    Oct 2008
    Location
    Goleta Calif
    Posts
    65

    440/550 custom build part III

    Oops, my bad! I scrolled passed his name. Thanks for straighten me out and good luck with your build.

  9. #9
    PWCToday.com Is My Home Away From Home fastgtfairlane's Avatar
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    Re: 440/550 custom build part III

    updates i know youre waiting for haha... got the nose reinforced for the most part, going to add one layer of cloth on the outside.. the front foothold is glassed in.. going to finish the tray and bottom tomorrow.. i decided to add a lil kicker at the back of the tray.. tubbies should be glassed on thursday and hoping to put some paint on this weekend.. i have until the 15th to have a running ski.. wish me luck

    IMG_20130430_165530.jpgIMG_20130430_165543.jpgIMG_20130430_192000.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 gto0209's Avatar
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    Dec 2009
    Location
    madison wi
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    Re: 440/550 custom build part III

    nose looks good! I like the glassed in kicker, the mat never lasts long when you make the kicktail out of underpadding. Can you glass over styrene foam like that? I thought I read somewhere that epoxy melted it?
    Charlie
    95 sc yami 760
    94 blaster 1100
    97 sj

    Looking for a complete coffmans sc pipe and waterbox, pm me if you have one

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