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  1. #1
    PWCToday Regular badrocco16v's Avatar
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    Oct 2013
    Location
    Detroit Rock City
    Posts
    52

    JS550 winter build

    Hello all,

    Sorry for holding out on you but I wanted to water test this machine before putting up a build thread to avoid having a 6 month thread that never wraps up.

    This started out as an 84 JS550 I bought from another PWCtoday member a couple of years back. I wanted to shorten the handle pole and install a rear exhaust over the winter and said, "why not put down some new paint too?"

    Here is what I started with.
    DSCF2248.JPGDSCF2250.JPG

    Got the engine out and flipped it upside down. The hull has seen better days. The impeller is a minty scat 15.5 and the bearings needed a little love.
    DSCF2257.JPGDSCF2258.JPGDSCF2260.JPGDSCF2263.JPGDSCF2268.JPG

    Now for the rear exhaust work.
    DSCF2269.JPGDSCF2270.JPG

    I found this sawzal bit works wonders for deturfing a hull. Just be carefull...it will cut into the SMC faster than I imagined.
    DSCF2274.JPGDSCF2273.JPGDSCF2275.JPG

    Next, test fitting a shortened handle pole. The second pic is it riveted and glassed back together.
    DSCF2279.JPGDSCF2285.JPG

    Aluminum exhaust pipe test fitted in place.
    DSCF2295.JPG

    Next my garage is converted to a body shop. Lots of sanding and glassing.
    DSCF2290.JPGDSCF2289.JPGDSCF2288.JPGDSCF2291.JPG

    First round of paint.
    DSCF2301.JPG

    To be continued.
    '84 JS550 Big Pin 750 twin carb, big pump swap, custom pipe by me
    '85 JS550 bone stock backup/loaner

  2. #2
    PWCToday Regular badrocco16v's Avatar
    Join Date
    Oct 2013
    Location
    Detroit Rock City
    Posts
    52

    Re: JS550 winter build

    Here's the hull after some paint on the top.
    20160328_181558.jpg

    The motor dropped back in nicely.
    FB_IMG_1459296218705.jpg
    Attached Images Attached Images
    '84 JS550 Big Pin 750 twin carb, big pump swap, custom pipe by me
    '85 JS550 bone stock backup/loaner

  3. #3
    PWCToday.com Is My Home Away From Home TheJS440's Avatar
    Join Date
    Jun 2014
    Location
    Seattle
    Posts
    2,049

    Re: JS550 winter build

    Know the paint color? I plan to do my ski up orange and purple, that orange looks nice.
    78 JS440
    -Ocean Pro Finned Ride Plate
    -Westcoast Intake Grate
    -SCR Ported Cylinder
    -Westcoast Exhaust Manifold + Pipe
    -Mariner Waterbox
    -Primer
    -SBN44
    -Quick Steer
    -Skat~Trak 16.5 SS Impeller

  4. #4
    PWCToday Regular badrocco16v's Avatar
    Join Date
    Oct 2013
    Location
    Detroit Rock City
    Posts
    52

    Re: JS550 winter build

    '84 JS550 Big Pin 750 twin carb, big pump swap, custom pipe by me
    '85 JS550 bone stock backup/loaner

  5. #5
    PWCToday Regular badrocco16v's Avatar
    Join Date
    Oct 2013
    Location
    Detroit Rock City
    Posts
    52

    Re: JS550 winter build

    Quote Originally Posted by TheJS440 View Post
    Know the paint color? I plan to do my ski up orange and purple, that orange looks nice.
    JS440, The paint is Lucid Technologies quadruzzi concrete orange. I bought a gallon a year or so back to paint a race car and used some of the left overs for the ski. I was thinking about doing yellow, but had the paint on the shelf.
    '84 JS550 Big Pin 750 twin carb, big pump swap, custom pipe by me
    '85 JS550 bone stock backup/loaner

  6. #6
    Frequent Poster Sxsixfitty's Avatar
    Join Date
    Nov 2014
    Location
    Michigan
    Age
    47
    Posts
    199

    Re: JS550 winter build

    Looks great!

  7. #7
    Frequent Poster AirJunky's Avatar
    Join Date
    Sep 2015
    Location
    Liberty Lake, WA
    Posts
    199

    Re: JS550 winter build

    Cool build. I liked it nekkid better.
    -
    Bill

    Current ride is an almost stock 94 550SX
    My JS550 build
    . - SOLD

  8. #8
    PWCToday Regular badrocco16v's Avatar
    Join Date
    Oct 2013
    Location
    Detroit Rock City
    Posts
    52

    Re: JS550 winter build

    So I've been holding out again. I picked up a big pin 750 and pump a little while back. One of my coworkers needed a running 550 motor so I started my swap a little ahead of plans. I already had all of the RHaas stuff for the engine and pump swaps. There was a slight hiccup in getting the x2 driveshaft ( i got shafted on CL) but now I have that too.

    Last weekend I decided to bite the bullet and do the engine half of the swap. All I was missing was a pipe. There has been a ragged FMP gold series pipe on the shelf from my old KX500 that I had no use for. I decided to section it out and make a pipe for the time being. Here are some pics of that franken pipe in progress. Once i got the pipe welded up (excuse the crappy welding, it was me running the torch rather than the guy at the shop who does proper finish welding) I mounted the 750 ebox toward the LH side per Kurt's recommendation and took it out to the nearby lake.

    The first water test was oddly successful but a little disappointing. The motor would not overpower the 15.5 scat in a 550 pump. Granted I didn't have the stones to top it out, it did have an impressive top end. Either way it was still fun.
    20160731_165952.jpg20160731_170003.jpg20160731_180130.jpg20160731_180203.jpg
    The next step is to take some of this fine 304 stainless and craft a pipe that fills up what little room there is between the 550 hull 750 motor and 550 fuel tank. Kurt has also offered some advise regarding the volume and packaging of this pipe. I plan on following this advise when making the real deal.

    It will probably be 2 months before I can do the pump swap so in the mean time I hope I can get the engine running strong.
    Last edited by badrocco16v; 08-11-2016 at 09:07 PM. Reason: double added photos
    '84 JS550 Big Pin 750 twin carb, big pump swap, custom pipe by me
    '85 JS550 bone stock backup/loaner

  9. #9
    PWCToday Regular badrocco16v's Avatar
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    Oct 2013
    Location
    Detroit Rock City
    Posts
    52

    Re: JS550 winter build

    I have some headway on my custom pipe.

    After months of procrastination and waiting for my friend's cnc plasma cutter to work, I just made a wooden template and plasma cut it by hand.
    20170410_173713.jpg

    Tig welded the halves together with an NPT bung to inflate it from.
    20170603_145945.jpg

    Then proceeded to fill it with water.
    20170603_155709.jpg

    Here is the first test fit after triming off the ends.
    20170605_211956.jpg

    Since I had the motor out, I went ahead and did the big pump swap. I'll tip my hat to RHAASS as the kit included all of the special fasteners and is a fairly simple installation. Anyone can do this.
    20170610_203803.jpg

    The final fitment of the pipe is still a work in progress. I'm planning on doing a center bleed to keep the noise within reason. I hope to post some more photos of a running ski in the next few weeks.
    20170611_131438.jpg
    20170611_131451.jpg

    *PSO kids don't try the hydroforming at home. It is too awesome.
    '84 JS550 Big Pin 750 twin carb, big pump swap, custom pipe by me
    '85 JS550 bone stock backup/loaner

  10. #10
    PWCToday.com Is My Home Away From Home BLRider's Avatar
    Join Date
    Apr 2007
    Location
    SE MI
    Age
    53
    Posts
    9,357

    Re: JS550 winter build

    Any ride reports of this bad boy?
    Never argue with an idiot, they will drag you down to their level then beat you with experience.

    Photos no longer being hosted by Photobucket.

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