Shonuff's 1996 SuperJet from Grand Rapids

[JustGood]

I wish i would have taken pics of my makeover of my race ski to freestyle. It belonged to Brad Maloney (owns Goggle Grip) So it wan't a filthy mess it was actually in very very good shape and i almost didn';t want to mess with it becuase of the shape. I will uploqad some pics as soon as i figure out how to in the gallery it says my size is to big. damn everyone tells me that women the x. ..... haha

 

[Shonuff]

Well, since I had the footholds glassed in, I needed to put something tough in place of the old gelcoat and I was thinking of doing gelcoat again but finding good stuff in a suitable color was proving to be very difficult so I searched and found this stuff called Coat-It from Goop/Tap Plastics.

Here's the .pdf on the stuff
http://www.tapplastics.com/uploads/products/pdf/Coat It Literature.pdf

It rolled on poorly, was a pain to work with, and dried to a bumpy, bulletproof, ugly grey speckled color.

One mixed can turned out to be plenty so I coated the top and bottom of the hull,

 

[Shonuff]

Refoaming a ski is as much fun as defoaming a ski is a PITA.

I purchased a kit of three pound expanding urethane foam from US Composites and used medium sized translucent plastic cups to measure and mix the stuff at 1:1. I propped the ski upright in my garage and tied the bow eye to my garage door frame for stability.

I mixed my foam parts, stirred the hell out of them, and poured the mix into the factory pour holes. It was about 95 degrees outside and about 90 in my garage. The mix began to slowly expand at about 40 seconds. I think I poured about four and a half cups per side allowing about twenty minutes between pours.

 

[Matt_E]

Foaming is fun.

 

[Shonuff]

Looking Good. :arms:

I didn't know you optometrists would get your hands dirty (or that you owned DeWalt Tools). Of course the only other Eye Doc I know is Idok, so maybe you understand my confusion. :cool2:

Really Nice Work.

And just so everyone knows, it was Royal Flush who suggested the Roto-Zip at PWCT. :woot:

 

[Shonuff]

Foaming is fun.

I love the little mushroom tops you grow on the mix cups.

 

[Matt_E]

We poured some leftover foam into one of those rubber gloves. It gets pretty hot though.

 

[RoyalFlush@PCB]

And just so everyone knows, it was Royal Flush who suggested the Roto-Zip at PWCT. :woot:

Did it work out well for you? I don't recall if I broke any bits or not. :boggled:

You are doing one HELL of a job. :biggthumpup:

 

[DAG]

looking great, keep up the sweet pictures and updates

 

[ski4]

absolutely awsome thread man.

this is what my last superjet was like when i got it/ YUK

 

[Shonuff]

The pulled engine was sitting on my bench still and I really wanted to get a feel for how it had held up so I returned my attention to it.

I removed and reconditioned the exhaust manifold and purchased new hardware and gaskets for it.

I found the starter to be in terrible, rusty shape so it was pulled, cleaned, the rust was ground down and out, the hardware was replaced, it was reprimed, repainted and finally all moving parts were lubed like crazy with grease.

 

[DAG]

damn, primed and painted the started.. this guy means business...!!! cant wait to see teh finished thing, in a year!!! lol

 

[Shonuff]

I was really unsure about what exactly to do with the carbs. Full Spectrums are big-time carbs and I was afraid of messing them up rebuilding them but I also felt that due to the representative condition of all the other parts, I almost had to rebuild them. The carbs were pulled and set aside waiting for the 44mm Mikuni rebuild kits to arrive from John Zigler.

The intake and reeds were next to come out.

When I got the ski home, it was really hard to start compared to how it ran at Opie's shop. When I pulled the reeds, I found out why: two had been broken and one of those had been eaten.

The good new is, I found Boyesen RAD reed valves underneath with the reed spacer so whoever owned it before Opie and myself installed the entire Boyesen/Full Spectrum Extream[sic] Velocity Manifold System with the carbs.:woot:

Props to Darin for pointing me towards the new three petal Pro-Series reeds from Boyesen. John Zigler got another call.

 

[onesojourner]

awesome thread man.

 

[Big Kahuna]

nice work

 

[yamaslut]

wow... freaking sweet write up

 

[Shonuff]

The electrical box got some attention last night.

Dear Yamaha: Please stop using those worthless pan-head Phillips screws on the electrical box and go with something that wont strip so easily and can be zipped in in and out quickly with a drill, like one inch #14 hex washer-head metal screws.

I thank you in advance. It would probably be better with SS, but I could only find Zinc. I am freshwater only, though.

I disconnected all of my electricals and moved everything to a newer case I purchased complete with gasket off eBay for $10.50.

I dielectric greased all connections and reassembled per MSDs instructions. The spark plug wires got pretty new OEM red sleeves and MSD boots from YAMACAT. The battery cable and starter cable were cleaned up well and got new clear plastic sleeves from Lowe's.

 

[sflsurfrider]

nice buildup thread!

just so you know, you dont have to use a phillips bit on the oem electrical box screws. a number 4 (i believe) square bit fits better and doesnt strip the heads.

 

[Frosty]

Coming along excellent Shonuff! Can't wait to see the finished ski... :biggthumpup:

 

[FL-cracker]

Awsome build! Glad to see it landed in a good set of hands. Shes gonna be better then mint once completed! Mad props!