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RESTO '96 SeaDoo XP – fixing stripped motor mount threads turns into restoration

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BumbleBee

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Hey guys,

My name is Andrew, I am the owner of a '96 SeaDoo XP. I bought the ski about two years ago from a guy on Craigslist for $500. The story was that the engine was a rebuild from SBT with less than 10 hours on it. The seller bought the ski from his buddy who started experiencing bogging issues a few hours after the rebuild, despite the carbs also being rebuilt. The seller had intentions of replacing the stock gray fuel lines and using the ski. However, he had a string of bad luck and needed to sell the ski. I drove 2 hours to see the ski and was quite pleased. It appeared to be somewhat clean and wasn't as bad looking as I expected it to be considering it was only $500. I was unable to do a compression test because the starter was also bad. The other catch, was that the seller never had the ski transferred to his name, so I wouldn't be able to get it registered initially. Even with all these minor issues my gut was telling me to take the chance and buy it. So I offered him $400 that day and told him he'll get the other $100 when I get a signed Bill of Sale from the previous owner. The seller agreed and I was on my way home with the ski.

After changing the starter, fuel, and fuel lines the ski ran great. Compression was at 150 psi in both cylinders. I did receive a signed Bill of Sale and registration card from the previous owner so I was able to transfer it to my name. I used the ski for roughly 1 year, and other than replacing the wear ring and impeller, it gave me no issues.

Unfortunately, last year when we were at the lake I noticed a vibration that was not there before. The front motor mount was missing both bolts that hold it into the hull. I found the bolts in the bilge and tried to put them back in, but the holes were both badly stripped. The ski sat all winter and all of this summer since I did not have time to repair it.

I have not been able to find any information about the best way to repair my ski. I could get another hull, but that seems crazy. I have some experience with fiberglass so I decided to give this a shot and see if it's something I can fix.

This thread will document all my progress. I will post several pics and videos to show my progress.

Please be kind, this is my first time making a threading with videos documenting my progress.

Enjoy!!
 
This the a mount with the problem. The mount itself is fine, but the holes into the hull are stripped.

upload_-1.jpg

Notice the hole on the right? I must have been filled with a caulk or sealant. I suspect the hole was already stripped when someone was tightening it down. And instead of fixing it, they just put some caulk or sealant down in the hole.

upload_-1.jpg
 
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Here's my first video...

It basically recaps what the pics above show...

[video=youtube;8zdQLXYOnsE]https://www.youtube.com/watch?v=8zdQLXYOnsE[/video]
 
Cutting into the hull!!!

[video=youtube;GoDrujyN9Pc]https://www.youtube.com/watch?v=GoDrujyN9Pc[/video]
 
I used my Dremel with a cutoff wheel to cut through the fiberglass.

upload_-1.jpg

upload_-1.jpg

upload_-1.jpg

upload_-1.jpg
 
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Just curious did you try to tap new threads one size bigger before you cut into it?
 
Just curious did you try to tap new threads one size bigger before you cut into it?

I considered it. That would definitely have been the easier route to go. But I was concerned about the condition of the metal. Turns out it was pretty corroded, I would've had to go 2 bolt sizes larger, but then the bolts wouldn't have fit through the motor mount holes. I was looking for a fun winter project anyway. And this will give me an opportunity to really go through everything on the ski.
 
Ill bet if the plate is in ok condition and I cant really tell from the video but if you can clean up the corrosion and bolt holes a helicoil kit would work, helicoils are replacement thead inserts, they are stronger than the original threads and you can still use your m8 bolt. Better yet a timesert ive heard are the best but ive never used them so i dont know much about it. I stripped my exhaust manifold bolts and I helicoiled them all and they are holding great, 18ft/lbs torque
 
Ill bet if the plate is in ok condition and I cant really tell from the video but if you can clean up the corrosion and bolt holes a helicoil kit would work, helicoils are replacement thead inserts, they are stronger than the original threads and you can still use your m8 bolt. Better yet a timesert ive heard are the best but ive never used them so i dont know much about it. I stripped my exhaust manifold bolts and I helicoiled them all and they are holding great, 18ft/lbs torque

Yes, that was my initial plan... But I decided to make my own bracket out of aluminum bar stock.

You definitely went big here

96 XP800!
Keep the 2 strokes alive!


yeah.. Hope I don't regret it...
 
There are shims available to level everything out. Just food for thought when your busting knuckles trying to get it exactly how it was



96 XP800!
Keep the 2 strokes alive!
 
Removing the plate and assessing my options.

[video=youtube;72MYcUuccN8]https://www.youtube.com/watch?v=72MYcUuccN8[/video]
 
Part out guys usually don't get this deep in parting skis. They usually give free hulls away



96 XP800!
Keep the 2 strokes alive!
 
Someone definitely painted the front on the inside of the hull white and purple isn't stock

Sent from my SM-G900V using Tapatalk
 
Aluminum plate is out... Condition of hole/threads worse than I originally suspected... Decision has been made to make my own plate...

[video=youtube;zvGLmWpYhnE]https://www.youtube.com/watch?v=zvGLmWpYhnE[/video]
 
[MENTION=57920]racerxxx[/MENTION] what grade of aluminum would you recommend for this?

Sent from my SM-G900V using Tapatalk
 
Part out guys usually don't get this deep in parting skis. They usually give free hulls away



96 XP800!
Keep the 2 strokes alive!

Yeah, that's what I found out from asking around... haha..

Oh well, it ended up being cheaper to make my own plate anyway...

Someone definitely painted the front on the inside of the hull white and purple isn't stock

Sent from my SM-G900V using Tapatalk

Okay, that's what I suspected. I haven't seen it in any pics of other XP's.
 
Video of the new plate I made.

[video=youtube;qXOaatP5LBE]https://www.youtube.com/watch?v=qXOaatP5LBE[/video]
 
What grade of aluminum is it? I would hate to see you use something to soft that strips out again

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What grade of aluminum is it? I would hate to see you use something to soft that strips out again

Sent from my SM-G900V using Tapatalk


hmm... I think I overlooked that.. I'll check my receipt and see if the grade is posted..
 
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