Jgorm's 04 ar230 build

[Jgorm]

I sprung 4 leaks in my welder! Hopefully my welding looks better when i go live!

 

[Jgorm]

I'm not done, but its going to work. It's not pretty but it will be strong. Tig welding is hard, especially with clamps and stuff in the way. Definite art.

I burned through in the worst spot!


I burned my finger pretty bad when the plasma shot sideways and burned through my cheap glove. Leather from here on out!



I cut holes so it will sit flush. The center pieces are about 1/4" higher than the ends. I ground down the ends. I tried to drill, but my mill isn't setup and it was really tough. 3 fresh sharpened bits didn't do much. Full body weight and slow speed. I'll 5200 it to the boat and add some big stainless bolts. This project took too much time! I probably won't get to the head install for a couple weeks. I'm going to finish up the clean out hatch area first. Jb weld the striped screw holes and add some weather stripping.

 

[Jgorm]

The results are acceptable. Not pretty, but strong. I got too many hours into this, but i learned a lot about tig welding and had fun.

Fusion on both sides, except for a couple holes in the tight corner that i couldn't get to.

I'm off to the river tomorrow to hopefully buy that fx140 and take it for a test spin.

 

[zipper]

The results are acceptable. Not pretty, but strong. I got too many hours into this, but i learned a lot about tig welding and had fun.

Looks very strong, if pretty is important, just touch the beads up with a small grinder.

 

[Jgorm]

I picked up the $1600 2002 fx140, 78 fresh water hours. It hasn't run for at least 3 years. i added 5 gal to about a half tank and took it out. It ran real rough for at least 20 minutes . Sometimes at half power. Later it started running better than my other 02 fx140. It cavities on launch a lot more, but goes faster and had better pickup on on plane. Speedo hit 56 57 a bunch of times, 10k rpm. I'll drive it through the summer and then attempt to remove the stuck spark plug. My 5yo son and 7yo daughter both stood up on a boogie board while in tow! I towed my daughter 20 minutes at 10mph while she cut back and forth on her knees with the boogie board. I bought an ho kneeboard on the way back from the river for 25 bucks. I can't wait to get the boat working! It was a super fun river trip.



The trailer has a cool box for lifejackets



It's a tight fit in this garage!

 

[Jgorm]

I retapped the threads after my butcher welding job. Hopefully i can get the back hatch done this weekend. I still need to make holes for the outside bolts.

 

[Jgorm]

Before cleaning

Stickers removed. I cleaned it with a green pad because the fiberglass was in bad shape. I put jb weld in all the hatch screw holes because a lot were striped. 5200d the ski hook with all stainless hardware.

New e-stop cord.


Shutoff valves installed on both engines

I ordered a jvc remote to replace the beat up stock controller and seal the hole.

I replaced the o rings with some i was surprised i even had.


I also got ez locks installed and the plugs cleaned up. Hopefully ill start engine reassembly tomorrow.

 

[Jgorm]

I spent over an hour trying to get the chain back on the drive gear with no luck. Got any tips?





I gave up on the engine for today and put a new seal on the fuel tank hatch.

I cleaned out the clogged up drain lines. They were full of dirt.

 

[Speedling]

I spent over an hour trying to get the chain back on the drive gear with no luck. Got any tips?
View attachment 77339
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I gave up on the engine for today and put a new seal on the fuel tank hatch. View attachment 77344

I cleaned out the clogged up drain lines. They were full of dirt.

You're awesome.
Unfortunately there are very few people that have had to do these things.
Is there possibly a master link?

 

[zipper]

@Jgorm I dont know if it will help...but here is a page from my 07 service manual.

 

[Jgorm]

Thanks @zipper the tensioner is already out, and the other guide. Maybe I'll make a couple custom tools. Like out of the large stainless i used for the ski hook. Ill round out the edge to fit the shaft, then build one more. I'm not sure if there is a master link, but i don't think that would make it easier. I did get the chain from one side to the other, so it's possible. It's probably easier with the heads off, but then i need to make sure it doesn't fall off when i thread the chain through the heads!

 

[zipper]

@Jgorm I assume you have a service manual for your year, as you have already gone deeper into the engine than most of us will ever go. I have more pages of torque specs. and timing chain and camshaft asm./disasm. for my 07.

 

[Jgorm]

Yeah, i had the fsm printed and spiral bound. No mention of this. They probably pull the engine and oil pan and just stick it on there. I'm hoping i don't have to do that.

 

[itsdgm]

I can’t tell from your pics. Is the engine in the boat? I’m assuming that it is. My guess is that you’re fighting the other timing chain guide that’s still in there. I have completely torn down an engine and do recall that there’s not a lot of room down in that space for the chain to squeeze around the case and crank. It might be possible though with some kind of long reach wire with a hook on the end and a scope to see what’s going on down there. It’s quite possible that the chain guide is in the way. Do you have access to a scope of any kind?

 

[Jgorm]

@itsdgm yeah. It's tight in there. Bi spent an hour yesterday with no luck. Your exactly right about the clearance on the chain guide. I know it's possible because i passed the chain from one side to the other. I bent up another 2 custom tools yesterday. I think i need to get out my torch and make a real custom tool! I can't get my scope down to see the clearance.


Nothing useful in the manual other than you don't need to remove the gear reduction.

I'm ready to get this together!

 

[Jgorm]

I got it! I used the other chain guide to feed it into the gear and a couple custom tools. Now i just needed to keep it there while i slip over the hg, then the heads. I might need to grab a helper.


My lockpick tool worked the best because i could bend it into shape in the boat.

I took my win and gave up for the night.

 

[itsdgm]

That’s awesome. Congrats

 

[buckbuck]

Won't be long now!

 

[Jgorm]

I ordered a $50 remote control for the $70 stereo. Seems silly, but rear deck control will be nice when swimming. I called a buddy at 1030 last night and he came this morning to help me knock out the heads. Got the cams and oil tank in too. I haven't turned it over yet, or done leak down, but i think it's good. I'm off to have fun the rest of the weekend.

 

[Jgorm]

I cut out at 1pm and got some work done before our 9yr anniversary dinner with my wife. I finished the clean out hatch area, with remote control all wired up. It's sealed up with 3m 4000, and the ports are greased up with lithium. Hose clamps all tight, and new weather strip installed.







I added 2 qts of oil (all i had) and double checked the cams against #1 tdc. I'm pretty sure I'm off a tooth on both cams. Damn. I'll rig up a better, more secure dial indicator holder and test again before i pull the cams. I'll probably leak test them too. The good news is the oil was pumping through all the holes in the cams. I almost lost the chain while turning it over without the tensioner! I forgot to order a gasket for that, but it's installed anyway until i get my new one.

I also looked at the fx140 trim and reverse bucket. A swap would be very time consuming because the reverse comes from the side on the ski, but the center on the boat. The ski looks like lateral thrusters!
Trim up

Trim down

Too bad place diverter doesn't sell a kit for our boats! I'd buy 2 in a second!