So I did everything...EVERYTHING! mentioned lol. All I can say is I was wrong. I admit it, I was totally not prepared to do what was needed to build around the pipe but I listened to what everyone was saying and now all I can say is, thank you to everyone for the positive replies, suggestions and support. Special thanks go to Octane, Wanderer, and Just Joe. You guys really stayed with me and helped out a lot. My first ride with it was basically....alright. Now it is alright...what did you guys do to my ski?! The power is just plain out sick! I spent 13 hours doing everything I could yesterday, and 5 more hours today with still a few little things to finish up. I did the following...
-tapped the pump and set-up dual cooling, one for the pipe and one for the head
-installed a Rule 500gph automatic bilge pump
-installed a second water bypass for the head and used the original for the pipe
-changed the cooling lines to Octane's recommendations
-pulled the carbs, cleaned them thoroughly, bored the jets to 140 main and 80 pilot with stock needle and seats and springs, installed new carb kits
-turned a 0.030" sleeve for the manifold to tighten up the pipe fitment
...all that plus running around to get little things here and there added up to a full 18 hours of modding and it was worth it. I still need to fab up a bracket for the head though. The little one I was using broke while out today. As always, there is going to be one little tiny thing overlooked. While I was out I noticed the bypass fitting stopped spraying water toward the end of the ride. After a few minutes the bilge pump kicked in but I noticed the water coming out was nice and warm so I knew the hose on the head blew off. I found a beach and stopped in, check and sure enough. I apparently forgot to put a clamp on that hose lol. Earlier I was wondering what happened to my little bunch of yellow zip ties, well I found them. They just happened to fall into the hull and wouldn't you know it, just when I needed them they turned up =) I slid a pair of them onto the bypass and it worked well. I did notice one thing though, it seemed to be at times a little rough and not able to clear out to hit the clean powerband. It was either rough sort of like it was loading up, or it was rough sort of like it was hitting the rev limitter. It seemed to be either/or at various times. Other times it was right on the money. It also seemed that the same condition occurred when I had to switch over to reserve until the fuel filled the lines. My thoughts were the screw settings are off. Right now they are set to 1 1/16 on the low and 1 1/2 on the high, does this sound a little too rich? I can dial in the lows easily enough, I only need to tune one and use a sync meter to adjust the other to match. But the highs might be a bit more tricky for me. Suggestions?