Slowest X-2 Build In History ...

[retroicon]

Hello everyone,

Alright, I'm warning you now that this thread is going to be long, drawn out, and I'll probably only make an update post to it every few weeks because this is going to take a while ...

Here's what's going to happen to the 1990 X-2 ...

PJS 800 Big Bore Cylinder
PJS "Works" Dual Resonator Waterbox
Billet Aluminum Case Blockoff Plates
Ceramic Coated PJS "Works" 750 Exhaust System ( Done )
Ceramic Coated PJS Exhaust Manifold ( Done )
New PJS High-Capacity Gas Tank
650 Cases Bored By Jr.Magoos ( At Magoos Now )
650 Flywheel Lightened by Jr.Magoos ( Done )
New Dale's Bad Attitude CDI
New UMI Steering with Quicksteer Plate
New UMI Bars with Odi Rogue Grips
New UMI Trigger Throttle
Dual Rule 500 Bilge Pumps Bar Mount Switch
Thru-Hull One Way Valve
K-Factory Lowered with Air Intake ( From Japan, I'll Take Pics )
Re-Routed Air Intake For Less Water Suckage ...
Modified, Lowered, and Sealed Hood - Carbon Fiber Re-Inforced With Internals Removed
Carbon-Fiber Re-Inforced Hull ( This is gonna be a pain in the ass )
Black Diamond-Cut Hydro-Turf
Stainless Steel Couplers
PJS Aluminum Nozzle
Wet Wolf Pump Cone
PJS Aluminum Battery Box
Blowsion Tubbies
Full Custom Paint

Right now the hull is in pieces in the garage and looking like hell, but at least it's a start. I have all the parts listed above here, and they're all going into the machine.

I'll take some pictures when I have the chance ... but the idea behind the build is to do a surf/freestyle X-2 with some real power, hull strength, and without taking in tons of water ...

I'll be back for more later ...

Gary

[onesojourner]

this is going to be an impressive boat.

[waxhead]

awesome sounds great
the k-fac stuff looks like quality gear as well

[WaHoo_1]

damn Gary....I remember loading that "new baby" into your truck when we were at Daytona. This will indeed be a hellva boat! Can't wait to see the progress and the final finished product!
:woot:

[D Slicker]

That is one hell of a to do list. Good luck

[retroicon]

the biggest pain in the ass is going to be figuring out how to reinforce the hull because ... well, the ribs are huge in an X-2 and the way the hull is made it wouldn't be a good idea to grind them down.

Got a little more work done tonight on disassembly and should be powerwashing the engine compartment soon. The hull is pretty much bare at this point, and keeps giving me more surprises. :-(

Found out that all 4 of the mounts for the battery box are cracked and/or stripped so I'm going to have to get creative there ... also found trashed pump bearings and a few other pump surprises that might have me looking for a new pump soon.

Anyway ... I figure it should be done just about the time the water starts getting cold. :-( I just don't have much time to work on it but I'm sneaking in an hour here and there.

I'll take a few pics of the work in progress. I have two hoods because I plan on getting creative on the first and hacking it up pretty good. If I screw it up, at least I'll have a backup ;)

[Legdragger]

"the biggest pain in the ass is going to be figuring out how to reinforce the hull because ... well, the ribs are huge in an X-2 and the way the hull is made it wouldn't be a good idea to grind them down."

I definately reccomend not touching the ribbs to reinforce, they are very strong. The area on the sides ahead of the motor mounts and up into the top deck is a good area to add a couple layers of glass. The nose is also a good place to add some strength while you are in there incase you nose it into the bottem. The rest of the hull is very strong as long as you don't land flat or pound it in chop. They X2 hull will fold just ahead of the foot wells if abused this way but I don't know how it can be stiffened there. It isn't fun to ride that way anyway but if you are trying to go fast in chop it happens. I have never damaged my hull in the middle and I have abused them a lot in chop.


"Found out that all 4 of the mounts for the battery box are cracked and/or stripped so I'm going to have to get creative there ... also found trashed pump bearings and a few other pump surprises that might have me looking for a new pump soon."

If you are looking to something different you could put the battery under the seat. It lightens the nose up a lot. It is a pretty simple relocation. Just get a ssealed battery of your choice and open the area ahead of the fire extinguisher to fit it just right with some turf around it. Took me two night to do. Make some long leads up with new wire and you are good to go.You have to completly cover the terminals with liquid electrical tape or it back feeds current through the water to the ground and up to the throttle. It you want to charge you batter just hook the charger to the leads that are under the hood.

"Anyway ... I figure it should be done just about the time the water starts getting cold. :-( I just don't have much time to work on it but I'm sneaking in an hour here and there."

Sweet, you should be good to go next time I get down to Daytona! We can shred the surf with the big bore X2's:Banane01: .

[WAB]

Wow, that does sound like alot of work. I had more planned for mine, but I just wanted to get it done and got in a hurry.
Are you going to run the dual PJS carbs that mount to the cyls? Seems they might hit the internal hull supports or the hull. My battery box screws stripped out also. I filled the holes with Epoxy resin and used new screws in there.

[retroicon]

Wow, that does sound like alot of work. I had more planned for mine, but I just wanted to get it done and got in a hurry.
Are you going to run the dual PJS carbs that mount to the cyls? Seems they might hit the internal hull supports or the hull. My battery box screws stripped out also. I filled the holes with Epoxy resin and used new screws in there.

Yeah ... I am going to run the duals and it's going to force me to move the CDI to another location, and modify the hood ( which was already going to happen anyway ).

I was thinking I'd do the same on the battery box ... I thought about moving it under the seat like Pete did, but I'd have to keep the strap mount that's part of the battery box and leaving a random mount would look odd to me .. so I'm just leaving the battery in the stock location.

[retroicon]

I definately reccomend not touching the ribbs to reinforce, they are very strong. The area on the sides ahead of the motor mounts and up into the top deck is a good area to add a couple layers of glass. The nose is also a good place to add some strength while you are in there incase you nose it into the bottem. The rest of the hull is very strong as long as you don't land flat or pound it in chop. They X2 hull will fold just ahead of the foot wells if abused this way but I don't know how it can be stiffened there. It isn't fun to ride that way anyway but if you are trying to go fast in chop it happens. I have never damaged my hull in the middle and I have abused them a lot in chop. .

Well ... I'm actually going to do a layer of glass, or two up front where you mentioned, and then I'm trying to go over the entire engine compartment with Carbon just for looks. Should be interesting ...

What do you mean about it folding ahead of the foot wells? Are you talking about that odd indented area below the footholds in the engine compartment. Where it sort of looks like it should have just come straight down, but there is a recess for some reason ...



Sweet, you should be good to go next time I get down to Daytona! We can shred the surf with the big bore X2's:Banane01:


That's the plan ... ;)

[Idok]

if you PM ewok, he has a bunch of X2 parts....

[Legdragger]

Are you going to run the dual PJS carbs that mount to the cyls? Seems they might hit the internal hull supports or the hull.

You can run a left side hull support to clear the carbs or a rediculously long quicksteer like I have. I ran it in Dayton with no support on the right and it was fine but for the hek of it I used an exta left side support on the right. You need to egg out one of the holes on the bracket on the bottem and tweak the top bracket a little. It touches the side of the hull way at the bottem a little.

[Legdragger]

What do you mean about it folding ahead of the foot wells? Are you talking about that odd indented area below the footholds in the engine compartment. Where it sort of looks like it should have just come straight down, but there is a recess for some reason ...





I have never witnessed it personally but I have heard fom multiple sources like Steve 802 and IDOK I think, about X2s that have broke in half right in the middle right where the seat goes upward to the bars. I have beat the snot out of my hulls and never had a problem so I wouldn't worry too much about. I can see it breaking there if you pound it in chop all the time in a raceing situation where you can't slow down to take it easy. Jumping surf shouldn't be a problem as long as you tail it in or nose it in.

[retroicon]

You can run a left side hull support to clear the carbs or a rediculously long quicksteer like I have. I ran it in Dayton with no support on the right and it was fine but for the hek of it I used an exta left side support on the right. You need to egg out one of the holes on the bracket on the bottem and tweak the top bracket a little. It touches the side of the hull way at the bottem a little.

I really can't see this being necessary based on when I put everything in the hull to do a mockup ... but I guess I'll find out.

[djyox]

Sweet, I'm gonna love this thread just like I did "Legdragger's" over on PWCT. I picked up a hull from zig, (bare hull) and it needs work, but its a project ski, and I want to build it up for the huge waves we get on the st. croix, so basically I want it built to ride in the surf.

[butti]

after a few years of wave jumping and general abuse ewoks hull finally started to break in daytona last year.that hull is still sitting in a junk pile.ill try to get some pics if i can remember

[retroicon]

after a few years of wave jumping and general abuse ewoks hull finally started to break in daytona last year.that hull is still sitting in a junk pile.ill try to get some pics if i can remember

cool ... then I'll know exactly where to go crazy on the reinforcing. I only weigh about 150, so I can throw an extra 10 lbs on the machine to strenghten the hell out of it and still be less total weight than most guys on their machine ;)

[djyox]

Post up pictures, cuz I got no idea where the hell my ass or head is when it comes to where to place the reinforcing!

Plus I weigh 190lbs, and I would take the extra weight to save the ski in the long run!!

[Yamah0]

Thats definetly one big to do list! When all said and done, minus the paintjob... whats the damage to the wallet if u dont mind me askin?

Thanx
Zane...

[retroicon]

Thats definetly one big to do list! When all said and done, minus the paintjob... whats the damage to the wallet if u dont mind me askin?

Thanx
Zane...

Honestly ... I have no idea. I don't really pay attention or I might get depressed. ;)

[Wetracer]

Hey Gary, you could at least post a few pics. Mike
www.Northwetpowersports.com
503-585-5675

[retroicon]

Hey Gary, you could at least post a few pics. Mike
www.Northwetpowersports.com
503-585-5675

I'm too damn frustrated with this POS right now ... :dunno: :aargh4: :aargh4: :aargh4: :indifferent: :pat: :chairshot: :thumbsdown: :puppy_dog_eyes: :hitwithrock: :buttkick: :omfg: :damnit:

[Legdragger]

This is where they break if you land flat from high up. Either don't land flat or reinforce the middle. I never had a problem until I went through growing pains learning to roll.

http://img.photobucket.com/albums/v436/racerboypete/Xhull002.jpg

[retroicon]

It's not that ... Here's where I'm at now ...

The hull is bare and I've started working on it, no real issues there yet. It's in rough shape, but I expected that ...

Two MAJOR issues right now.

1. There are 4 bolts that hold the steering assembly to the metal brace/reinforcement that's up under the top ... all 4 snapped when trying to remove them. It's like they were made of plastic or something ... old ass metal. So ... I have two choices.

A. Just JB weld over the top of the snapped off parts, and leave the damn thing in there. Blast it, while still in the hull, with a pressure cleaner and hope nothing up there ever breaks.

B. Somehow figure out if there's a way to remove that metal brace/reinforcement so I can get it on a bench, drill out all 4 bolts, and heli-coil it, or just re-tap with a bigger bolt.

Issue 2. I'm doing the PJS 800 Big Bore Kit and have all the parts I need ... everything. Sent the top half of the cases to Paul at Magoos and he machined the cases, and clearanced the pistons. Epoxied up the cases and sent them back in great shape.

So, I put the cases together, and then I go to take out the studs to replace them with the longer studs for the PJS cylinder. Well ... some jackass apparently thought that JB weld would make a good replacement for loctite beacuse all of the studs were JB welded in. I got all but 2 out ... of those two, one snapped, and the other wouldn't move no matter what I did.

PB blaster on that thing for 2 weeks, heated it up to bright red, impact stud puller ... nothing. Finally, that one snapped and I see the reason for the JB weld. The threads in that stud hole are almost entirely gone so I'm gonna have to heli-coil that one ... or, send out a new top half of my cases to have them machined and epoxied.

Thoughts?

[yamaslut]

It's not that ... Here's where I'm at now ...

The hull is bare and I've started working on it, no real issues there yet. It's in rough shape, but I expected that ...

Two MAJOR issues right now.

1. There are 4 bolts that hold the steering assembly to the metal brace/reinforcement that's up under the top ... all 4 snapped when trying to remove them. It's like they were made of plastic or something ... old ass metal. So ... I have two choices.

A. Just JB weld over the top of the snapped off parts, and leave the damn thing in there. Blast it, while still in the hull, with a pressure cleaner and hope nothing up there ever breaks.

B. Somehow figure out if there's a way to remove that metal brace/reinforcement so I can get it on a bench, drill out all 4 bolts, and heli-coil it, or just re-tap with a bigger bolt.

Issue 2. I'm doing the PJS 800 Big Bore Kit and have all the parts I need ... everything. Sent the top half of the cases to Paul at Magoos and he machined the cases, and clearanced the pistons. Epoxied up the cases and sent them back in great shape.

So, I put the cases together, and then I go to take out the studs to replace them with the longer studs for the PJS cylinder. Well ... some jackass apparently thought that JB weld would make a good replacement for loctite beacuse all of the studs were JB welded in. I got all but 2 out ... of those two, one snapped, and the other wouldn't move no matter what I did.

PB blaster on that thing for 2 weeks, heated it up to bright red, impact stud puller ... nothing. Finally, that one snapped and I see the reason for the JB weld. The threads in that stud hole are almost entirely gone so I'm gonna have to heli-coil that one ... or, send out a new top half of my cases to have them machined and epoxied.

Thoughts?


just ride your super jet........

[Legdragger]

Did you try heat on the steering bolts? Maybe you can pull the steering off over the busted bolts if you get them hot and then turn them out with them hot. Then again the thing you really want to get hot is what they are threaded into. I wouldn't try to hard on that hull. I would think there would be another hul around you could get cheap enough to toss this one out.

If you need some 650 cases I can hook you up for the cost of shipping. I will give you the set so they match each other.

[retroicon]

alright ... got the stud out of the case ... FINALLY!

The steering is another story ... all 4 bolts snapped after about a quarter turn, and they snapped below where I can grab anything. I'm not sure what it's called when the threads don't go all the way to the head of the bolt, but that's how all 4 of those were. Each of them snapped just about that location so I'm just going to fill the holes with JB weld and hope the bolts the threaded parts of the bolts hold up long enough.

As for the super jet ... it's in pieces right now too. :-(

You won't recognize it next time you see it. ;)

[yamaslut]

alright ... got the stud out of the case ... FINALLY!

The steering is another story ... all 4 bolts snapped after about a quarter turn, and they snapped below where I can grab anything. I'm not sure what it's called when the threads don't go all the way to the head of the bolt, but that's how all 4 of those were. Each of them snapped just about that location so I'm just going to fill the holes with JB weld and hope the bolts the threaded parts of the bolts hold up long enough.

As for the super jet ... it's in pieces right now too. :-(

You won't recognize it next time you see it. ;)

you should know better than that... ripping apart two skis at once..
:bigeyes: :bigeyes: :bigeyes: :bigeyes: :bigeyes: :bigeyes:

[felix5oh]

Just keep it going it's never to slow. I went on a 18 year hiatous from jetsking. Focus on your X2 while your riding something else. You'll get it, bro.

I wanna see the finished product.

[retroicon]

you should know better than that... ripping apart two skis at once..
:bigeyes: :bigeyes: :bigeyes: :bigeyes: :bigeyes: :bigeyes:

It's in pieces ... but could be put back together in about an hour if I get the itch. Been doing too much travelling on business lately :-(