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RESTO 96 and 97 GTX Build

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Ok so I tried to take some pictures but not really the best. I had some stuff to do when I got home today so I just had to take some quick ones. I split a quart of gel coat between the two skis but I should have done some more per ski so I could have done a second thicker coat. When up on the ski, you can see faint areas where I covered the scratches so I think a second coat would help. I think spraying it would help reduce the sanding effort need. If I were to do it again, I'd consider trying to spray it.



 
I think some of the areas that look porous could have used more sanding and/or a second coat. I wasn't too concerned with it since that part of the ski should be in the water for the most part :thumbsup:
 
Cool, that looks good for rolling it, WAY better than before. Did it set up fast? How big of batches did you mix
 
Thanks! I did about 150-200 mL at a time. We rolled it on about 11pm on Saturday night then started sanding it around 10am Sunday.
 
I used a 3" wide high density roller. I got paint cups so I could measure how much I was using at a time and so I knew how much hardener to add. Make sure to get the stir stick covered in gelcoat before adding the hardener so the stir stick does not soak up the hardener.
 
I'm currently working on the top gel coat of the 97. In the picture below (I posted this earlier in the thread as well) that the gel coat was in horrible condition. The gel coat literally was peeling off as I sanded it. I purchased the Snow White gel coat from Jamestown Distributors (P/N FIB-5700). After applying the quart I bought over 2 coats, it looks alot better. Although it looks better than before, I noticed some thin spots after sanding it with 400 grit. I've decided to purchase another quart to thicken the gel coat. I think once I'm done, it'll come out great.


Before:



Its windy today and didn't clean it off before putting it in the garage today so don't mind that:



Some of the areas still had water in the picture. The additional 2 coats will really make it look new.
 
Well I got the seat covers on the 96. I just need to add some more staples, finishing some pulling in spots and do some trimming on the rear seat. I'm pretty much done at this point with the 96 until the engines get back. I'll be able to concentrate on the 97 until then as well. The gel coat I ordered this weekend should be here tomorrow so I'll start that process.

Here's the 96 with the new seat covers installed. Probably not the best job but it was my first time doing it.

 
Thank you! I appreciate it. It was a little tougher than I thought it would be but overall looks good. I forgot to post but I also purchased ODI 120MM Ruffian handle grips for both of the jet skis. I'll post some pictures when I get home (my work blocks Photobucket). They are a small change but definitely add to the look.
 
Update: Well I figured it would be a good time for an update. I have progressed well with the project. I have received one of my engines from SES and expect the other one to be delivered today. The 96 got its engine installed this past weekend. Both jet skis have been moved back to the trailer. I purchased an alignment tool which will be delivered today as well. I'm thinking by the end of this weekend, I should have both jet skis just about finished. I still have some work to do to finish up the hood on the 97. I tried to hook power up to my info center gauge to test it but I'm not getting anything. The LCD film doesn't look wrinkled but it does look dark like it was on the verge of wrinkling so I'm hoping thats the only issue with that. I repaired the one on the 96 last year so I'm familiar with how to do it.

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I'll load the pictures in with Photobucket tonight. The page won't load on my work computer.
 
Took a half day vacation on Friday and worked on the both jet skis pretty much the rest of the day and throughout the weekend. I got the 96 fired up yesterday (just a quick start in the driveway). I'm having a fuel pumping issue on the 97. I'm thinking since the carbs are dry after being rebuilt, they are not wanting to pump. I primed the fuel line so I know there is fuel getting to the carb but I'm not getting any suction at the inlet of the carb. I'm going to fill the carb with fuel and try again to see if I can get it to pump. The rebuild kit is OEM parts from OSD, the check valves were installed with the ink on the UP side as the instructions stated and seem to be seated well.

Since I had never hooked a battery up to the 97 since I purchased it, I was pretty happy to hear the 2 beeps when I hooked up the DESS key. I'm thinking once I get the carbs to pump fuel, it'll start right up.
 
I was able to get the 97 running yesterday. I primed the carbs with fuel and cranked it until I was seeing fuel come out of the return line. It was smoking excessively but I think there was excessive fuel in the engine when I was trying to prime the carbs. I'm thinking once I let it run for alittle bit, it'll clear up. Ofcourse now that I'm pretty much ready to take them to the lake to let them run and break the engines in, it is supposed to rain all week.:facepalm:
 
Well I feel at this point I can say the majority of the restoration is completed. There are some things here and there that I will progressively work on. I need to get them both in the lake and get the engines broke in but I feel like I'm ready for summer!



 
Just read this tread and would like to say that you did an awesome job on these. They are beautiful skis. I'm using this thread for inspiration for my upcoming rebuild. I just picked up 2 1998 xp limiteds that need some tlc. The body work on mine are in decent shape and only need a good buffing so that should make it a bit easier than yours. I love how yours turned out. Sounds like it was a lot of work but the hard work payed off. You just gotta get out and use them. If you don't mind, what was the cost to get each engine rebuilt.
 
Thank you! I did put a ton of hours in them. I spent $900 on each engine plus $75 shipping on each engine and about $25 total in materials to ship them. I'm ready to get them on the water but I have a wedding I'm in this weekend and have to travel to D.C. on Sunday so it'll be next week sometime before I can. Let me know if you have any more questions.
 
For the parts I would have needed, the $900 per engine for a full rebuild was worth it to me plus each engine has a 2 year no fault warranty.
 
Finally got the skis down to the water yesterday. The 96 started up and ran great on the trailer while in the water. The pisser was putting out water great. I set the idle to the correct RPM. I let it run for about 20 minutes while playing with the throttle gently. When I moved over to the 97, I hit the start button but the engine would not turn over. Pulled the plugs and it turned over but the PTO was gushing oil. Immediately I knew that I had a bad crank seal. Got the skis home, took the carbs off and sure enough, the PTO side was filled with oil. Since the season is here, I plan on putting an inline valve on the oil line that I will shut off when not running the skis. I talked to Tom at SES and he agreed. I kept the line open overnight to see how bad the leak was and it only filled the PTO back up alittle bit so it isn't a huge leak. I'll pull the engine this winter and have it repaired as I don't want to have to wait to ride both of them since riding season is here. I plan on draining the PTO again and getting everything back together then taking it back to the lake and letting it run.
 
Glad you got them splashed. Sorry about the bad seal. That really sucks. Nice that it is a no-fault warranty. So if you forget to open the valve, you won't loose. I have heard of people hooking their key to the valve when they shut it so they won't forget to open it. Break those puppies in and have a great summer! Hopefully we can get together and ride. Missed you on Norman. (just to rub it in again). Shamu was the only GTX there.

Don
 
I have a 97 GTX in great shape just did same thing new engine does a nice 55 on the water, now took on a 2001 GTS needs top end rebuild, or new engine, not sure which way to go, enjoy your ski looks great
 
soccerdad said:
Glad you got them splashed. Sorry about the bad seal. That really sucks. Nice that it is a no-fault warranty. So if you forget to open the valve, you won't loose. I have heard of people hooking their key to the valve when they shut it so they won't forget to open it. Break those puppies in and have a great summer! Hopefully we can get together and ride. Missed you on Norman. (just to rub it in again). Shamu was the only GTX there.

Don
Click to expand...

I wish I was there! I was watching the forum on my phone while doing the wedding stuff. The pictures looked great! You're right about the no fault warranty. Its definitely worth the money to me for the comfort haha. I'll definitely try to make the next get together.
 
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