SXR1500 Project - Fixed Steer

Once I finished the mounting plate - I had concerns about downward forces from the handle pole being supported by the plastic latch. So I created “shoes” that fit under the handle pole. I used UHMW Polyethylene plastic bar. The stuff is stupid hard and doesn’t absorb water. The downside is – it’s hard to form. You can cut it or mill it without too much fuss. But if you want to sand it or file on it – to get a good tight fit - it’s really tough to do. I managed to create the two parts and then mounted them to the underside of the handle pole. The steering cable area got really tight. But I have clearance for everything. It’s close but it all fits.
 

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For the pole covering I used some light carboard to create a template. I picked up a sheet of polypropylene from McMaster and cut it to size. I was planning on re-purposing the original fiberglass parts, but it’s going to take a lot of cutting, fitting, filling, and sanding to get it done. If this steering setup works, making a nice pole cover may be next winters project. But for now, I’m trying to keep it simple. It's starting to look "industrial" right now. But I think once I get everything painted and reassembled - it will at least look acceptable.
 

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I got lucky with how to mount the warning lights. I found a “gland” used for routing solar panel cables though the roof of a vehicle. It was only 10 bucks and the warning lights should fit in the holes without any issues. I wanted to mount it close to the handle bars. But the angle is wrong for actually seeing the lights. So I’m mounting it down by the pivot – where I can see it. If it looks ugly, I can always move it. Again, keeping with the concept – inexpensive, simple, and proof of concept for ride quality.
 

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I just came across this (at the top right of the page) and it just reminded me of your SXR. http://www.krennpowersports.com/jetskis-for-sale.html

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I get anxious when life gets in the way and things get stalled – and it’s been a couple of weeks since I could work on the ski. But I have a few weekends free now and the project is really coming together. I found myself jones-ing to finish the assembly w/o paint and get it out on the lake for a quick ride. I really want to see how this mod works. But then I checked the lake temp of where I usually ride – 47 degree’s !! Even with my new wet suit – that’s still way to cold for my blood. So back to the garage to finish the fab, then paint, and then reassemble.
 
I mounted the light pod on the pole cover using waterproof epoxy to bond it in place. I opened up a hole on the underside for the cables. I might have to make it bigger though. I finally reached a point where I needed to tear everything back down for paint. I rattle can’d the pole parts in black. I used Krylon Fusion to paint the hood cover white and the pole stops green. The Fusion paint is supposed to be for flexible plastic. The green on the right pole stop really "orange peeled" when I put the second coat on. Not sure why it did that - the part was fully dry and it only did it on one side. So we shall see how it holds up. If it starts to flake off – may look at some type of a vinyl wrap.
 

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I’ll give the parts another couple of days drying time and then start the re-assembly later this week. I have several items that need to be finalized during reassembly like; routing and retaining the stop/start switch wiring, doing the same for the fuel vent hose, and making sure everything is clean and dry so I can blue Loctite everything. Stay tuned – it’s all coming together……….
 
I used these small blocks as threaded anchors inside of the handle pole to bolt on the steering cable mount and the handle pole lock down bar. As you can see from the pics I added a threaded hole on the side of the block and then used a long piece of all-thread rod as a “handle”. I was able to simply align the holes and start the bolts. I then unscrewed the all-thread rod before tightening down the mounting bolts. The system works pretty well.
 

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When it came time to install the steering stem, I may have gone overboard, but it’s the steering system. So better to be careful and let something come loose.
 

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I found a little extra time this week to try to finish the project. I routed the electrical cables. I know that a lot of OEM’s will try to reuse items to keep the part number count to a minimum – but the lead on the start/stop switch is way over kill. It must be 7 feet long. But I managed to take up the slack in the bow. I routed the fuel tank vent to the end of the handle pole. And finally, the top cover is in place. Everything is ready now – but spring is slow to arrive. So it may be a few weeks before I can get it in the water. I will try to get some video when I do get it out. Thanks to everyone that followed and commented. Hope that you enjoyed the project.
 

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WFO Speedracer

A lifetime ban is like a lifetime warranty !
Location
Alabama
Everything looked great till you screwed that plastic cover on top of the handlepole, IMO it detracts from an otherwise awesome build, on one I did I used diamond plate and sanded the diamonds down some, something along that line even if it was just flat sheet or cut down the stock plastic cover and reinstall it , it would make it look a lot better.
 
Thanks for the input Speed. When I first laid the piece up for fit up - i kinda thought the same thing. It's a big white canvas. Kinda sticks out like a diamond in a goat's butt. So I started searching the inter-web for some type of decal or graphic. So far I've come up empty handed. But at this time, I'm more concerned with the steering stem placement. I think I might have gotten the bars too far forward and/or that the steering stem is to "vertical". While I was able to stand on the ski while it rested on it's - I felt that I might be a bit to far forward in the tray. I'll have to wait a few weeks to launch it and find out.
 

WFO Speedracer

A lifetime ban is like a lifetime warranty !
Location
Alabama
I used to make steering stem for X2'S that used an offset BMX bicycle steering head that the bars bolted to, a setup like that would move the steering back quite a bit. maybe something to look into AJP in Belgium makes a replacement steering head but I believe it is still straight vertical...................... https://www.facebook.com/photo/?fbid=1579661642378677&set=gm.3044608532532637


Also looking at your setup you could easily make a stepped aluminum piece that fits inside the handlepole that your plate bolts up to and just move the whole setup back some.
 
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Well - the weather has finally started to warm up. I was finally able to get my ski out last month for a "shake down" run. To my surprise and delight, it handled pretty good.
I'll post more video on my next ride.
 
Finally found some free time this weekend to take a longer ride. The weather was way warmer.
 

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