550sx to 750 "All or Nothing" build

holygoat

Site Supporter
Location
Indiana, USA
I just came in, I'm just exhausted. Temp in my shop.....in front of fans..= miserable! Anyway, I got some brackets screwed down. I got some pads cut and glued down. I marked and V cut the center pad under the gas tank so it would sit flat in the hull. Got the waterbox strapped in and exhaust hose run. Also got the pole bracket and fuel neck installed. Now I pretty much can't do anything until the driveline is installed. DANGIT!

What material for those pads? Looks nice. Glued down with Weldwood?
 

Myself

manic mechanic
Location
Twin Lakes AR
Little update. I got the replacement impeller and still had issues. I set up a stand on the workbench and tested runout on pump shaft, completely dis-assembled the pump to make sure ALL bearings were fully seated and square, tried another pump shaft........came to the conclusion possibly it was in the driveshaft splines this whole time. Another driveshaft is on the way and hopefully this will solve it.
 

Myself

manic mechanic
Location
Twin Lakes AR
I got most of today in working on this project. Pump is mounted, driveshaft and bearing/seal installed, engine dropped in, and all of it lined up to perfection!
 

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Myself

manic mechanic
Location
Twin Lakes AR
I tested the starter and it sounded pretty weak......took it apart and found the main brass power strap broke. Well, I had another starter here that worked good but had boogered gear teeth. SOOoooo, I took 'em both apart and made one good one!
 

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Myself

manic mechanic
Location
Twin Lakes AR
And since everything is in it's permanent home I mocked up the exhaust so I can decide exactly where I want to cut it. Do you HAVE to cut it.........NO. BUT, I want it bent and pointing straight at the waterbox inlet. Plus I wanted to add a bit more volume to it as well.
 

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Myself

manic mechanic
Location
Twin Lakes AR
I got about 5 hours in today on the exhaust. If you remember WAAaayyy earlier I might have eluded to a special trick up my sleeve for it. Well, the stock 650sx pipe does NOT point the right direction for the waterbox inlet. AND,....I wanted to add a bit of length for a better overall power delivery but the pipe belly sits TOO CLOSE to the gas tank. Adding a bit of length to the cone should still add to the lower end power while also adding a bit of RPM for better peak power. This 750 setup should like that. Cut, form, weld, and paint today. Pipe is done!
 

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Myself

manic mechanic
Location
Twin Lakes AR
I got a few more hours in on this build today. Of course it was already sweltering hot because first thing I did was run over to a buddies shop to help check out a no reverse issue on a 700r4 in his 72 Chevelle. I found a stuck spool in the reverse boost valve, and a couple valves in the valve body were sticky as well. Hopefully I got that sorted for him. Anyway.........I got the steering nozzle, cooling, and siphon hoses hooked up on the pump. The stock siphon hose is too short to reach with a 750 pump swap. You can see I just added a barb and a short section of hose. I also set the steering cable right in the center of travel and locked down the adjusters on the extension that comes with the 750 pump swap kit. You can also see in that pic that the modded 750 steering nozzle fits nicely with plenty of clearance to the hull.
 

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Myself

manic mechanic
Location
Twin Lakes AR
After that I fit the intake grate and ride plate up. The ride plate was all good no issues. The intake grate needed some fine tuning. I'd guess for most folks a fat bead of silicone and mount it up is "Good Enough". Well, I don't do things like that. The edge of the pump shoe was making some contact with the radiused portion on the intake grate (marked with sharpie) so I got out the die grinder and clearanced a little at a time until it fit nice. With that done, the rear of the intake grate would hit JUST the edges of the ride plate BEFORE being fully seated in. In the closeup shot you can see how the ride plate edge sits just a bit higher than the pump surface. A wee bit of careful grinding on that as well. And now the bottom side is finished out.
 

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holygoat

Site Supporter
Location
Indiana, USA
Looks excellent as always. Looking forward to seeing it finished. I can't wait to fix my ski up properly over winter. I've been sort of half assing things to get as much ride time in possible, then I'm gonna come back through and finish it up properly in winter.
 
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