How do you deal with bonding the new surface that was created over the foam to the existing hull? There has to be mechanical bonding somewhere otherwise you might as well make a mold of your superjet and pour foam in it??? Assuming I followed through and made the best jet ski ever the most optimal thing to do would be to splash it in to an original bottom deck. But what approach should I take for dealing with bonding the foam braced glass to the existing hull?
You have to overlap the new glass over the old glass. For example, with my X2, I did a nose fill. I filled the nose with foam, then I glassed over it going up the sides about 4" (pretty much to the bond rail). That worked well, but the next year, I cut out the stock hull from the inside, then reinforced the new nose from the inside, going up past the bond rail.
That is why I say it will be heavy and weak. Your repair will be about twice the size of the hole you are repairing. So even if you removed the stock hull, you will likely end up heavier than you started.
Also, when you secondary bond from the outside, you change your body lines. You are making those areas thicker. Splashing a secondary bond can be problematic because you slightly changed the shape in the process.
There is an alternative method that is twice the work but can make the ski end up nice from the outside. On the fuel fill area of my X2, what I did was, I filled the area with foam and shaped it with bondo like a plug. I then taped off the hull and waxed just the bondo. Next, I glassed over the bondo with minimal overlap, about 1/2". Then I went through the inside of the hull and cut out the stock hull and removed the foam and bondo. I then taped off the stock hull and waxed my "mold". Next I glassed over my "mold" and to the stock hull. Lastly, I ground off the edges holding the "mold" in place and did the body work to blend the new area to the hull. A lot of steps, I know.
As you can see, if you want to modify your ski, it may be nice but it wont be a perfect plug. If your intent to sell a splash of your work, you will need to either grind off the reinforcement to correct the changes in the body lines, or you need to get another ski and just make a nice plug.
There is no reason you can't foam, glass, foam, glass, cut, glass, etc. Just understand what that will result it. Think out what you want to do and how you are going to make it happen. You may still want to make changes after the fact, but you want to try to minimize those changes.
