Eric's 91 Freestyle square nose

[Metal4130]

I bought this ski last year in late august and I am now really kicking it into gear to get this done before Lainer. I am about 3/4 of the way done but I though I would start my own thread showing my ski's progress. I have shown you guys bits and pieces of this built but I'm gonna compile the whole thing into this thread. It will take a day or two to post pictures from the begining to where I am now. I hope you enjoy it!

Heres What I started with!

[Metal4130]

Here is some of the details of this ski. The owner really did a half a@@ job on this ski overall, the paint is chipping and it is dirty as all hell. I bought it off ebay for 500.00 dollars with a buy it now. I picked it up that next day.

[Metal4130]

I got right to it and had the whole thing taken apart by the next day. Back when pwctoday was good I surfed and searched and started to do the reinforceing. Grinding thoese ribs was bad, so much dust and a smell you will never forget. This parts was the first I had ever really worked with fiberglass but i think it turned out good.

[cookerq62]

gotta love the over spray on the prop and the lag bolts holding on the intake grate. what other surprises have you found?

[Metal4130]

Here is the finished Reingforce job with some blue dye added to the resin. It came out real good. Oh and that 17oz biax fiberglass mat.

[Metal4130]

Next I bought a set of Watercraft Factory "old style" footholds and began installing them. They didn't fit perfect so I used some rivets and pushed them into place. After the rivets I sealed it all up with 3M 5200 sealand and applied some strips of fiberglass around it. These turned out pretty good also.

[Metal4130]

This ski was a 1991 and when I dug in for the footholds there was water dripping out. So I had to re-foam the whole ski. This task was very easy after I bought a small die grinder with a wire wheel on it from Home Depot. Again very dusty and extremely messy

[Metal4130]

While I had the tray all apart I figured I should just install a scupper too. I used ther 2 inch check valve set-up from Home Depot. I got all the fitting from Home Depot and it worked out well. In order to get the rear thread on fitting to sit flat I had to heat up the PVC and Bend it a little bit. After that I sealed it all with 5200 and installed it.

[Metal4130]

I also found an expandable 2 inch plug to cover the scupper when the ski is docked.

More

[Frosty]

Very cool man... looking good. I love the blue dye trick... I will have to remember that one.

[Metal4130]

Time to continue this. I wanted to take a break from hull work for a while so I made this internal fuel fill. I got the matal clunks from jetskisolutions and i got the fuel tubing from mcmaster carr. The stainless tubing came from my local hobby shop. This went together nicley and there were no problems. I cut the neck off the fuel tank and opened it up a little and put the stock fuel cap in there and sealed it with some 5200. Then i just gor some hose clamps and a rubber tube from Home Depot and made the rest. The pictures tell the story really.

[Metal4130]

a few More

[Metal4130]

finally

[SJ/XPBri]

That's the first time I've seen an internal fuel fill done that way. It looks awesome :hail:
Bri

[Metal4130]

Here is my version of the slutty hood mod. I made 6 hand hulds really just for looks. After I finally got the old hood liner out with a chisel and grinder i reinforced the sides of the hood. I then cut out the louvered vents and blucked off the hole. I blocked off the stock intake holes also. I then cut out the 6 handholds and made custom buckets for them. I made a cardboard template and then covered them in duct tape so that the fiberglass wouldn't stick to it.

[Metal4130]

Here are the custom buckets.

[Metal4130]

Heres what the outside looks like.

[DaUpJetSkier]

looks sweet, what are you doing about getting air into the engine?

[Metal4130]

the hood is not fully done yet put i plan on having breather tubes

[Frosty]

looks really good bro...

[MADMAT]

Nice build pics. This stuff is soooo muchhhh workkkk!

[Freestyleriverrat]

Damn man......cranking that stuff out. Good job!

[Metal4130]

Starting to prep for paint tommorow! I made this booth with 1 inch pvc pipe and 2 rolls of duct tape. I still have to put the door on tommorow. Hopefully tommorow everything will have a coat of primer on it.

[DaUpJetSkier]

what did it cost you in materials for the pvc booth?

[Metal4130]

it was 40.00 for the plastic about 12 for the tape and i got the plastic free from my dad.

[D-Roc]

who sell those slippery ski covers? they are sweet but i never seen them forsale anywhere.

[ketsair]

who sell those slippery ski covers? they are sweet but i never seen them forsale anywhere.
anyone that is a dealer for parts unlimited watercraft:biggrin:

[2lick]

how did the pvc paintbooth hold up.... how did you vent or did you get a lot of over spray