96 Speedster Build Thread

[ohtenwillys]

I wanted to use this to dump pictures for my new-to-me 96 speedster. Since picking it up yesterday, I've pulled out the STBD engine for a rebuild - previous owner said the valve shaft gear/crank gear were stripped, so we'll see. Gonna need lots of cleaning and a reupholster and some other goodies...

 

[ohtenwillys]

Oops.. forgot to post the engine on the floor..

 

[4x15mph]

Can't wait to watch this. You must know a lot about the Sea Doo's to take on this project. Include pics of the Willy's also!

 

[itsdgm]

Looking forward to seeing your progress.

 

[ohtenwillys]

Can't wait to watch this. You must know a lot about the Sea Doo's to take on this project. Include pics of the Willy's also!

Haha honestly the only thing I know is from research and talking to people. I've never owned a boat or ski, my parents never had one either haha. I do have some formal diesel mechanic training, a degree in marine engineering, and work as a mechanical engineer so hopefully SOME of that will help. I just hope I'm not in over my head

Oh and the jeep's gonna be on tow rig duty so as soon as the hitch comes in I'll post towing pics!

 

[ohtenwillys]

So with the engine on the hoist I started pulling off externals. I broke off 5 out of 9 of the flywheel cover bolts but there's still shanks sticking out of the flywheel housing I can vice grip onto. I couldn't get the headbolts loose with my electric impact and didn't feel like kicking on the compressor so I stopped there. Everything turns smoothly and there's no abnormal play between the crank and the valve shaft. Previous owner said that is what was wrong so we'll see once it's all apart.

 

[ohtenwillys]

I had trouble getting the headbolts off so I borrowed a better impact from my boss aaaaaaand....SNAP SNAP SNAP
In other news, tow hitch, wiring, and mirrors for the jeep came in so hopefully ill get them on tonight and take the boat to the carwash and pressure wash the engine bay

 

[4x15mph]

So are you going to try to use a bolt extractor to take out the broken bolts? Any tips and tricks will be great as you go through this incredible restore.

 

[ohtenwillys]

Yeah I'm gonna try to get them out, but I'm already coming to terms with buying a rebuilt. If the crank is messed up, then it seems like the same amount of money to rebuild myself with top and bottom end than just buy a complete rebuild. I'm doing some research right now to see whats the best idea. Any suggestions would definitely help.

 

[4x15mph]

I like the idea of a rebuild since that engine looks worn a bit. Bolts breaking, etc. A new engine is probably only $1000-$1500 (premium). Keep going!

 

[ohtenwillys]

I'm looking at going with a rebuild, i've read a few threads and its between SBT and SES. Before i do that, i still need to get the flywheel off and it won't budge UGHHH. On the positive side, I got the jeep in full tow mode! Need to get new shorter shocks, I already bottom out without any weight on the rear end.

 

[ohtenwillys]

OH btw... if anybody has any suggestions on how to take off the stupid flywheel, lemme know. I'd use heat but I don't wanna burn up the coils.