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I just repainted my 2002 sj hood. Used metal 2" putty knife and scraped down to fiberglass. Wet sanded 600. Used 2k 2 part epoxy in a rattle can. Used 2 cans of OEM from color-rite.. followed with urethane 2 part gloss clear in a rattle can. Judge for yourself.

Whatever you do dont gut the waterbox. Water will end up in the motor.

I considered cutting the stock in / out on the OEM waterbox and weld 3" tubing instead??

Exhaust transition needs a little engineering. I can help you with what worked for me.

Trying to keep the new vinyl stealthy.

Tshank - unfortunately the only way to get the motor out is to break it way down. SJ 1200's are measure by the millimeter. No extra room. I think I can get it out, repair exhaust clamp and back together in 20 hours. Spent 6 months wrenching already. Looking forward to riding this ski.

Starts right up. No choke needed. Idle is even. Sounds big and linear. Ran my ported and piped 701 also. They are completely different.

Ran ski on hose today. Waterbox is leaking around the hose connection. Will need to remove the entire motor to get the tank out. :(.

Only cooling lines and case ground to finish. I did fire it up yesterday. Sounds big and fast. Lol

Finished. Final gloss. This was the most time consuming part of the build. I think it turned out. Ok. I will apply OEM decals in 4 weeks.

What happened here????? Anyone? Urethane 2 part primer follower by color rite OEM blue. Turned white after 10 minutes. Thinking if it doesnt cure blue within 24 hours I might need to 600 wet sand and color coat again. I have 2 part urethane gloss waiting. I have low radiant heat on it right...

liquid graffix surf seal. no glue. removeable. easy install. 10 seconds. $30ish.

I need 3 bolt angled carb air filter adapters. Im running 38 SBNS. If anyone knows where I can get them please post up. New or used. My current setup wont clear the girdle.

I know a couple guys have been waiting on this transition. Here you go. Assembled exhaust. Clears manifold and hull. Perfect. Modified an inline strainer to accept 1/2" line. Ordered standard Yamaha graphics for the hood. Added my own "SJ1200" decal underneath the "YAMAHA".

Tshank. Sanding sucks. 10 hours. Its perfect. I have 2 part primer, oem blue and 2 part clear ready to go. I just need stock (ish) graphics. I want this build at maximum sleeper.

With the oem airbox your pop off pressure should remain close to stock

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I used a 2" thin metal putty knife and tapped that with a rubber mallet between the hood and liner. It cut like butter. The only hang up was the glue underneat in the center of the hood.

How is your build coming along?

Thanks guys. That's what I will use.