Jgorm's 04 ar230 build

[Jgorm]

I'm starting a thread to stay motivated and make a strong push to have everything working this summer. I'm trying to do something every day.

I bought the boat in December 2016. Took it out for 2 days and it had trouble starting the second day. Found out it had bad compression and milkshake oil. I side lined this project, bought a river house (project), and bought a fx140 for last summer, planning on engine this winter. That engine had some issues so i side lined that and moved back to the boat. I finished raising the metal boat shade at the river up 5' so it fits the tower. There river is now ready for the boat.

I pulled the heads nearly a year ago and finally dropped them off at the machine shop yesterday.


Trailer work

• Flushed all the old grease out.
• Installed bearing buddies (reese copy)
• New goodyear load d 205/75/14 tires on order (5). The old tires are in terrible shape. 05 date codes on some. Bad cracks, etc.
• Cut out the inner fenders that was rubbing on the tires. Link
• Look at brakes and determine they are in bad shape and abandon fixing them. The river is 5 minutes on flat ground, so brakes won't be needed.

Boat

• Find and install at least 5 nuts on the back of the cleats that fell off! I used locktight on them. Difficult to get to the front ones! I had to send my wife in.
• Got a new handle for the boarding step.
• Ordered a new radio jvc $70

 

[Jgorm]

Today i got the fenders back on the trailer, installed the ladder handle, and hooked up the stereo. I'm gonna run a switch for the turn on lead over to the helm so i can flip the tower speakers when i want. I think i can use the old remote wires in. Of course jvc decides they need to change the shape of the plug on different models! Bastards.
Old stereo

new stereo

It sucks climbing into this hole! I barely fit, barely.

 

[Jgorm]

I also ordered a scupper valve and i need to find a spot for a 10" woofer.

 

[Ronnie]

The pics in the helm bring back some memories, some of them bad ones, no pics were taken of me at the time but I'm sure I wasn't smiling.

I found the area under the throttles in the SX 230 HO I owned was the perfect place for a 10" to 12" woofer. I checked the depth by drilling a few pilot holes and used an uncooked spaghetti noodle as ruler but you may be able to reach back there from the helm.

 

[Jgorm]

Yeah i was looking in there. I'll have to seal up the cup holders really well to make sure the back wave won't cancel the bass. 5200 should do it!

 

[Jgorm]

One step closer. It's going to be really tight but i think i found clearance. I'm going to probe with a few pilot holes as suggested. My cardboard template was within 1/8 of the speaker and i had to move it up a few inches so the hull would clear. i marked off the flat part and the throttle

 

[Ronnie]

Have you consider moving the location so that the speaker is behind/aft of the throttles? It looks like it would give you at least another cup holder’s width of room.

 

[Jgorm]

I have. The back side over there is not nearly as flat because there is an extra piece of wood in the fiberglass. The fire extinguisher hole will need to be covered up. I also couldn't figure out how to get the extinguisher holder out of there.

 

[Brandon_SC]

subscribed... Keep up the good work @Jgorm !

 

[Jgorm]

I spoke to the machine shop about the heads . Pressure test passed! (No cracked head)
My leakage test was not as good. 1+2 we're around 8%. 3 was 55% and i didn't get 4. Over 5% they needed to machine the heads because lapping won't fix it. They are going to disable, hot tank and inspect. Probably looking at 400_700 in machine work, so not bad for a boat! Under a thousand doesn't count on boats.

 

[Jgorm]

Just got back from the river. It's boating season! Went swimming a few times. Lots of people in the water with boats and skis. Back to the boat tomorrow.

It was probably the last offroad trip, but way fun! I got some lights installed in the Viking.

 

[zipper]

I spoke to the machine shop about the heads . Pressure test passed! (No cracked head)
My leakage test was not as good. 1+2 we're around 8%. 3 was 55% and i didn't get 4. Over 5% they needed to machine the heads because lapping won't fix it. They are going to disable, hot tank and inspect. Probably looking at 400_700 in machine work, so not bad for a boat! Under a thousand doesn't count on boats.

You are right...B.O.A.T.=Break Out Another Thousand.

 

[Jgorm]

I got the new trailer tires back on the trailer and have the hole cut for the sub. It totally hits the back and sticks out 2"! What am i gonna do? Just kidding, it fits fine. The only rule for cutting giant speaker holes is don't f up! I had about 1/2" at the tightest spot. Now i need to figure out what screws /bolts i should use on the sub. I'm thinking about 5200'ing some 3/4 ply behind the sub on the flat parts. Then I'd feel safer with wood screws to hold in the sub.
The tightest spot was about 1/2".

Thanks @Ronnie for the spaghetti tip! Worked great!




Plenty of throttle clearance. I pulled the cables back into the rear seat area.


I'll cut some cardboard templates and overlay then in this.

 

[Jgorm]

Any thoughts on modifying the extinguisher holder into a port? Seems to be a decent size and good location. I'd cut off the bottom and leave the top open.

 

[Speedling]

While you got them out, perhaps check out the throttle drop fix in the FAQ.
https://jetboaters.net/threads/throttle-dropping-check-here.299/#post-2412

 

[Jgorm]

Today i cleaned up the itchy fiberglass, cut the templates, then the plywood. I decided to double it up for strength and so i can use wood screws instead of bolts. I'll test fit tomorrow, then glue them together. Hopefully i can 5200 them in on Thursday.

 

[Jgorm]

Still have a lot to do!

• Finish sub
• Buy and mount amp
• Wire switch to helm for tower speaker amp
• Do throttle fix
• Install shutoff valves
• Install scupper
• Get heads back, install, time cams, install exhaust, etc.
• Add oil, plugs, etc
• Install spare tire carrier
• Weld bow stop.
• Wash, wet sand, buff, polish, and detail entire boat.
• Sleep

I've been working until 1030 or 11 and i wake up at 430 for work!

 

[Jgorm]

Just spoke to the machine shop. Bad news. 2 exhaust seats on #3 are badly corroded (had lowest compression). Probably needs all new exhaust valves and seals. He's going to count how many intake valves i need. Looking at $800 in labor and another 600+ in parts. Too bad they don't sell complete heads! Probably needed another week or 2 to get parts and install.

 

[Brandon_SC]

@Jgorm Sorry to hear... Keep your head up, brother... we are rooting for you.

 

[buckbuck]

hmmm...kinda supports our idea that #3 valves stay open when the engine shuts down and moisture from the exhaust tends to rust items in the cylinder.