SX/SXi/SXi Pro planning refoam and install footholds

[GReenANt]

2010 edition winter project

(this was 2009)

I'm planning a build on my 98 sxi pro to install footholds and refoam and will be doing a few other things while its all ripped apart

in all i will be doing these things
1. New foam (sealing everything and maybe glassing inside rail)
2. Footholds
3. closing holes from fire extinguisher tubes
4. installing a footstrap
5. sealing leaky holes from removed hull extensions (i'm gonna put threaded inserts in so i can take them on and off)
6. turfing


i'm only in the planning process and want to be prepared so don't have to go back in and redo anything.

my main question involves the tray,foam,and footholds.

i have seen a few ways of doing the main parts but i wonder what you all think the best way to do it is

1. Pour foam,shape for tray, lay down a new tray, then do a traditional install for the footholds.

1b. pour foam shape for holds and tray. then lay in a layer or two add holds and do a final layer

2. reglass in old tray and new footholds, then pour foam in the old extinguisher holes. (concerned with foam causing tray to curve up)

will be my first time Glassing and may try to reinforce bondline for practice before doing the tray although it will be under the turf

 

[tom21]

number 2- put something heavy on the tray.

 

[GReenANt]

i guess i will plan on trying that unless i find the tray is cracked i suppose it will save on materials

what is the recomended weight and style of fiberglass for the bondline and tray (something able to do everything is preferable but if its better i can layer different things and get different types)

 

[women sit down]

Me and Rkm did this to our skis last winter. It was ALOT more work than we planed but it payed off. Are you planing on buying to molded footholds

 

[GReenANt]

decided that i don't care enough about this particular ski to spend the money and time on a complete re-foam so i only installed footholds and then glassed them in being a 750 i foamed behind the holds as well. (glad i did because the foam i removed was bone dry way to go kawi)

thats all for this break during spring break i plan to turf and possibly install a strap i'm not sure on the strap though. if i turf without it i probably wont do it because i want the turf to be clean

also does hydroturf sell perfectly flat pieces of turf because i would buy it to put below the underpadding because removing the underpad was the worst part of the whole process.

 

[GReenANt]

Footholds

1. turf, rails, pads removed
2. steadier version of pic 1 (the bushing was stuck)
3,4 engine pics not doing anything just becuase some people might be interested\
5. Trinity holds trimmed down and glued in

 

[GReenANt]

footholds

1. footholds glued and clamped may have gone overboard on the rivets but after foam only one spot had foam come out
2. old fire extinguisher tube cut up with hold sticking in soon to be filled with foam
3,4 Halogen lights to keep the epoxy warm overnight was like 50+ without but it sped up the drying
5. old pic for reference the hull extensions and extended rideplate were removed previously

 

[GReenANt]

footholds

foam complete only needs some fiberglass and turf and to put some plastic pieces back on

second pic is the carnage from removing the hull extensions sad thing is i probably would have been better leaving them on (one year old)

 

[jondotcom]

foam complete only needs some fiberglass and turf and to put some plastic pieces back on

second pic is the carnage from removing the hull extensions sad thing is i probably would have been better leaving them on (one year old)

What did you do with the hull extensions?

 

[N3vrSat1sfied]

foam complete only needs some fiberglass and turf and to put some plastic pieces back on

i would glass them in for sure. Better now then later. You will love the trinitys!

 

[GReenANt]

i've still got em i think they are homemade but they are solid and clean and for now i want to keep them i am considering putting inserts in the back of the hull so i can take them on and off.

 

[GReenANt]

upcoming plans

i would glass them in for sure. Better now then later. You will love the trinitys!

i actually glassed them in as soon as the foam was hardened it was such a nice day. i just have not taken a picture of it yet, and wont be able to for a few weeks. I first saw them on your build thread it was probably what convinced me to install them on my 750 (tubes were not as big a deal as i thought) I definitely think i will like them after a little trailer riding

i was home on break and that was the second to last day i had to work on it.

i'll be installing hood-straps and turfing the tray one weekend soon and then hopefully going to my roommates lake house for spring break in TN. if i have time ill turf the rails then otherwise i will wait.

 

[N3vrSat1sfied]

If you turf the rails the easiest thing is to do like one side at a time and clamp it down over night. The rear corners are very difficult to get to stick i had to reglue mine after the first ride. I think there on there now, Hopefully

 

[GReenANt]

clamp the top and sides?

will be using heat gun, rubber mallet, hot knife, and cutting edges at 45 so they don't catch water. also considering painting and leaving the front bumper on because i can always put turf on later and i have to crank the ski up a 45 degree angle and i don't want the rope wearing out the turf and making it look like crap

Craig i was wondering how many layers of glass you put over the tube holes in the back to make it watertight and strong enough i've already put two of 6 ounce e glass using us composites epoxy

 

[N3vrSat1sfied]

i just clamped the sides down. The top stayed down.

Travis was doing most of the glassing on my holds i honestly dont remember how many we put on.

 

[GReenANt]

long weekend of turf

friday night drilling holes and clearing/cleaning front of tray

saturday 10am to 9pm (with some breaks) doing all the padding and turfing the bottom.

sunday 3-7 turfing the sides and then cleaning

padding took awhile all by myself and then cutting and dryfitting the turf so i didnt screw up so far its been a good first try without too much wasted

gotta finish up this weekend hoodstraps, limit rope,new bilge switch, turf inside holds, small gaps, and put back e-box and fire it up. if i have time i will turf the rails, and i will got a small piece of aluminum to make a homemade quickturn.

 

[GReenANt]

pics

also next turf job i will do front then sides then bottom should come out cleaner that way.

any reason to seal the holes from the hoodstraps , and the primer ?

 

[GReenANt]

finished straps and limit rope as well as reloacating fire extinguisher, turfed the holds for now and bilge switch. some turf to be done later(if i get around to it) also put the battery in and fired it up. once the gas got to it she ran like new. and now i know why its called fogging because it filled the garage with white smoke in about two pulls on the throttle.

 

[N3vrSat1sfied]

turf looks good. let me know where you put the fire extingisher. I dont have one in my boat.

 

[GReenANt]

zip tied it to a battery strap loosely and used a single thick wire with one twist to hold the top to the side.

will post a pic eventually