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  1. #91
    steve45's Avatar
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    Very nice!

  2. #92
    My name is Sean and I am addicted to STXs smokeysevin's Avatar
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    Old minor update. Added tank pads, waterbox beauty rings, waterbox back strap, front fill cover, tank turf, tank straps.

    Sean














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  4. #93
    My name is Sean and I am addicted to STXs smokeysevin's Avatar
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    Sean Scrambles to Satisfy Standup Success (general assembly and progress update)

    Time Spent:
    36 Hours (over a few days.)

    Tools Used:
    90% of my stock

    Tools Properly Put Away:
    54%

    Materials Used:
    Who knows at this point? I have sure as hell stopped keeping track of what it has cost...

    PPE Used:
    Appropriate for Tasks
    Safety Sandalls

    Number of scratches added to fresh paint: 16

    Total swear words directed towards jetpump/shoe: 750,469

    Percentage complete:
    60% (I think I am starting to get over the hump on this, it is getting really close but I know the last 10% takes 90% of the time which is why I plan to sneak up on it by convincing myself I am really only 60% there. Crazy like a fox)

    I have finally started tossing stuff back together, summer is getting long in the tooth and I am sick of this thing being strewn across my garage, not making brapp noises.

    Last week I got the motor torn down. I gave the jugs a quick flogging with a dingleball hone, then thoroughly flushed them in the parts washer. The crank got new seals and new piston pin bearings. The pistons got dunked in the ultrasonic cleaner until they were decarboned and then tossed onto the crank with new rings. The motor got all new gaskets thanks to our friendly neighborhood @JetManiac and I pressure tested until it held as intended (Big Pin 750 Rebuild Quesitons).

    While I was waiting for the threebond to dry on the cases, I rebuilt the pump with a kit I picked up from @brapperdoodle (gracias amigo) and learned how weird the 750 pumps are compared to modern setups. I only had to take the pump apart once to figure out what was wrong so that was nice. The pump got stuffed with a 10/16 Hooker (750 Swap Prop Recommendations)

    I got some shiny new cooling line fittings and placed an order for my "fuel line" to connect the cooling system up but that got held up in USPS limbo. (Cooling Line Recommendations)

    Even though I had already installed glued in, and flared the cooling lines on the inside of the hull, I had done none of those things on the outer section. That made things super fun to cut and flare the lines with the limited space in the tunnel space... I ended up "clearancing" my flaring tool with my angle grinder so now it is a custom tool. Something tells me I won't get my tool deposit back from o'reilly's anymore if I were to try and take it back.

    Installing the jet pump proved to be a massive pain, the gasket on the front of the pump REALLY didn't want to slide nicely into the shoe, I ended up using some RTV to glue the gasket to the pump, then add a slight lead in chamfer to the gasket. I also added a slight lead in to the shoe which was a tricky thing to do since it was already glued to the hull... not too bright of a move on my part. There is almost no room to install the pump hardware once the cooling lines are installed. I found out after installing the pump that I had cut the cooling/bilge lines longer than I should have so fitting that hose is going to be a real pain but it should be possible without pulling the pump. Learn from my mistakes on this one...

    To stay busy, I started working on throwing stuff together again. I got my coil plug leads sleeved and terminated with self-extinguishing wire sleeving from wirecare and new MSD plug ends from Jegs. Hopefully I did the plug leads right, this was my first time doing them but it seemed relatively straightforward.

    That stuff done, I checked over the motor and found out I had the wrong starter bendix (I had swapped it with a kawi 4 stroke one which spins the opposite direction) installed so I got to take the flywheel back off and replace it with the OG that came with the motor. The cold fusion flywheel lock came in handy so I am glad I kept it.

    Crisis averted, I started fitting the controls and upper pole vent/passthrough. The stock tube was drilled out and removed and I had originally planned on using some kanaflex but the specific version that I bought (a year or so ago...) was too stiff and I didn't like how it popped when the pole went from fully down to slightly up. I ran to holmes depot today and picked up some 1-7/8" ridgid shop-vac hose and set to work making that make sense. I ended up chopping the "threaded" section of the coupler off, sanding the OD down to fit inside a 1.5" long section of 2" ID silicone connector then smushing that into the hole I cut in the pole mount. The vacuum hose itself is about 1.5 feet long and is free fitting inside the 2" SCH 40 pvc pipe I replaced the stock tube with. To install the pvc pipe I had to add a clearance recess into the lower section of the pole and "persuade" the tube in. I then took a 2" pvc coupler and coped it at an angle to match the angle of the inner pole structure to give the new tube something I could attach it to the pole with.

    Once I was happy with that, I grabbed one of the many kawi runabout start/stop switches and spliced an extra 1.5 feet of wire in the middle then sleeved it with braided shielding. The kill switch wiring, 750 throttle cable, and steering cable were then run down the tube and the pole was installed along with one of the wax racing pole locks. I have a 2000 seadoo XP choke cable on the way to wrap up the controls side of things.

    Remaining Items:

    cooling line install
    fuel line install
    stinger outlet install
    wiring
    bilge pump
    battery cables
    reinstall vin plate (removed for painting and because it fell off...)
    install other side graphics
    install rego numbers
    throttle/choke cable mounts
    cut/seal exhaust tube
    fab/install opposite side "exhaust" blockoff plate

    Sean


    2" Sch 40 24" long tube


    Tube Clearance and Hose Spec


    Installed Stickout


    Coped Locking/Locating Flange


    Installed Passthrough


    Vacuum Hose "threaded section"


    Hose Clearance and Install


    Pole Lock from Wax Racing


    Bolted in and aligned and sleeved coil installed. I did have to clearance the aluminum bedplate because the stinger coupler for the exhaust is really big.


    Room for activities? Ignore the non-stuck hood seal...


    Purdy.

  5. #94
    steve45's Avatar
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    Looking good! Don't stop now!

  6. #95
    My name is Sean and I am addicted to STXs smokeysevin's Avatar
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    Wiring is done! "Modern kawi spec" with oe on/off switch, all oe style sumitomo sealed connectors, and "open concept" mounting. All the components are potted and fully sealed so should hold up to the hull environment. Fingers crossed, this will hold up as well the 4 strokes do.

    I also fabbed up a throttle and choke cable mount and installed a 98-2000 seadoo xp choke cable to go with the 750 sxi throttle cable. I am currently waiting on the umi throttle cable adapter before I can get that wrapped up.

    Wax racing bilge switch mount with blowsion rotary switch, and rule 500 auto bilge installed to keep the water out.

    Side note: wiring is really hard to take pictures of, especially when it is fully installed...

    Remaining items:

    Seal driveshaft fitting
    Install bilge pump mount on hull
    Trim and glue exhaust tube in place
    Install fuel tank straps
    Install battery straps
    Trim choke cable
    Fab upper choke cable mount
    Install fuel tank and fuel lines
    Install exhaust hose clamps and bead roll tubes
    Weld exhaust stinger for 2" pipe
    Glue exhaust tube in
    Seal sponson mount access hole

    Goal is to be water ready in 2 weeks.

    Sean











  7. #96
    steve45's Avatar
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    Amazing!

  8. #97
    My name is Sean and I am addicted to STXs smokeysevin's Avatar
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    Soon

    Sean

  9. #98
    steve45's Avatar
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    It's ALIVE!

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  11. #99
    My name is Sean and I am addicted to STXs smokeysevin's Avatar
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    Quote Originally Posted by steve45 View Post
    It's ALIVE!
    It is really close now. I have lots of little detailwork to wrap up but that was a big milestone for me.

    Super good way to end a wednesday after work!

    Sean

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