"Project Sportster" - Build-up & Mods

[cnpalmer]

Well since I was new to the forum a couple months ago, joined as a premium member and really appreciate all the help and feedback I've gotten I figured I'd share my project with you guys.

I purchased my 2003 Sportster LE on 3.14.09. It was VERY dirty but started up and I thought I got a good deal for it at $3500 with the trailer. :hat:

I started work on the trailer right away. Added 2 new 5.3x12's and checked bearing and seals. Greased em up good too. Replaced the entire wiring with a new harness and wrapped everything in loom and zipped tied it every 3'. Also used shrink tubing on all connections for added waterproofing. Took 2 days for the trailer work and cleanup on it but it looks real good now and might get a fresh coat of paint at some point. :hurray:

After a lot of cleaning I was ready for the engine service. I'm not familiar with these engines so I thought it best to have an authorized Seadoo dealer perform the check up.

The service cost $150 for a typical tune-up, oil, compression check (120 across both cyl.), plugs/gap, lube.grase etc. Found out the starter had to be replaced. It wouldn't turn over any more, just clicked at the relay. Also had the loose choke cable replaced and the electrical box in the engine done too. After adding in a fitted baot cover and 1 gallon of the XPS-2 oil my service topped off at $1125! That's with parts & labor.:ack:

Got the boat back at the house and am now starting on all the mod's & upgrades I've gotten for it! :hurray:

First off will be the Sony stereo install ($500+). I purchased a head unit, wired remote, amp and 6, 6.5" speakers! Just need to find space to install 6 speakers in the little hull! Anyone have suggestions? I'll take pics of the install & progress. :coolgleam:

Second, my Hydro-Turf, molded diamond/dark gray, ($275) is ordered and will be here next Monday! I'll take pics of the install and progress.

Third, LED's are gonna my next purchase/install. Gonna go with 2 floods for under the negine hood, 2 spots for the back deck near water level and 5 mini's for cupholders/dash and then 4 3" strips for under the rear seats and front seats. Again I'll post pics of the install & progress.

This is gonna be one fun summer I hope. Anyone have any suggestions about additonal mods, things I've done, things I should look at etc. etc. please let me know. I have my old starter & choke cable if anyone is interested I can ship it out to you if ya wanna rebuild or need parts.

Here's some pics of the boat the day I got it, during the clean-up and the stereo equipment.

 

[RFoster130]

Did ya get the hydro turf yet? I want to order it tomorrow and I am torn as to which texture and color to get. I am leaning towards the dark grey molded diamond.

 

[SeadooBOB Square Pants]

I purchased the black grooved and I really like it. I think the grooved works great, because when you wash the boat clean-up is a snap. Spray the hydro and all the dirt and crap literally drains out of the the scupper valve, the grooves act like tracks for the water. I have my dogs on the boat sometimes and my boat is clean after every wash, nothing left behind. Good luck with all the speakers hope your battery can handle all the juice you will be running. If you have questions about the LEDs I am part way finished with mine and already very happy with the result what a deal!! If you can pull it off I think a couple speakers behind the seats would be bitchen, unless that was the plan already then just disregard.

 

[cnpalmer]

Project Sportster - FIRST RUN! (5.21.09)

Well last Thursday was the first day i was able to get out of work, have decent weather and the boat was back from the dealer and ready to go. :rofl:

Took it to a smaller pond here in MA (Hampton Ponds) just in case I had to row back to shore for anything!

Trailering the boat wasn't bad and laucnhing it was pretty easy too. I need to adjust the brakes on my Jeep though, the ride kept slippin' back on the ramp even with the e-brake on and the tranny in 1st! :ack:

Well I got her out on the water and man does she fly! Started right up, took it easy at first just to get used to the feel. and about 5min. in I was at WOT! (53mph!) :reddevil:

I had a blast for the couple hours I was out. Brought her back in to get ready for day 2 on the CT river for the holiday weekend.

Attached are pics of me and my girl out with in that day.

 

[cnpalmer]

Project Sportster - Speaker Install (5.25.09)

Well after having the boat out all weekend, I took yesterday with a buddy of ine (Mel) to help out with getting started on the stereo install.

Great day for it too. Started out cool but sunny and really got warm by mid-afternoon.

We started with mapping out and measureing (at least 5x each side!) where the first 4 speakers would go. I have 2 more left, but will hold off until I hear how 4 sound!

We drilled, carved and drilled some more. After a ton of work and about 6 drill bits later we had all 4 holes done, buffed and sanded down. Then we ran the wires and cripmed and sjrink tubed everything. Then I installed the baffles for the speakers and screwed in the stainless hardware.

The outcome is IMO a very clean and well built install. Should sound solid with the addition of the baffles and the speaker install should hold up to boating conditions.

I have some good poiinters/tips for anyone doing an install on one of these if you're interested. Especially tool choices, wiring needs, and good prep & cutting tips.

Attached are pics of the install, my buddy Mel and the finished product. Next steps is the head unit. amp and wiring that up.

 

[cnpalmer]

@rfoster130 - Turf is going to be delivered today! I will post pics of that install as well. I went with the molded diamond just becauseI liked the pattern so much. The color choice, since there are only 2 for that pattern was between black and the dark gray. I thought too much black would throw the look of the boat off and the dark gray matched the gray seats perfectly. I asked a few friends what they thought and they all said the gray as well.

@seadooBOB - I have the rear seat off now so I can drill holes to bolt the amp up in the engine compartment behind the driver's seat. It was the best place I could find. the last 2 speakers there might just work!!! Thanks for the suggestion. Actually, on your LED's what are you using for a switch assembly and where are you mounting it?

 

[cnpalmer]

Hydro-Turf & Amp Install (5.26.09)

Well I received my Hydro-Turf kit in the mail yesterday. It was sitting at my front door when I came home from work. :hurray:

I opened it up and I am VERY pleased with my choice, molded diamond in dark gray/charcoal. I have everything in my basement laying out to try and get the "curve" from being in the shipping box. I wish the weather here in MA would cooporate with me so I can get it installed! :boxing_smiley:

I worked a bit more too on the stereo install. I mounted the amp behind the driver's seat using some bolts and nylon threaded nuts along with a few washers to provide as much surface coverage for support on the fiberglass. Looks good to me and the bolts don't stand out too much when I put the seat back on. :chillpill:

I also got the bracket for the head unit and need to run the wiring for that. With the weather I was hesitant to install the unit in there.

All that's left is RCA's, power, ground, terminate the speaker connections and run power/ground for the amp. Hopefully will be ready for the weekend.:ack:

 

[RFoster130]

Lookin good!!!! I decided on the same molded diamond dark grey hydroturf. Ordered it today. Let me know how that project goes.

 

[mark osborn]

Hello I the sportster 2006 model do you have any ideas to make it quicker.

 

[cnpalmer]

@RFoster - It's alying out in the cellar still. Too wet up here today to attempt an install. It did stop bending/curving a lot when I lifted up the various boxes and paint cans I had on the pieces. A day or 2 more and they should be really flat.

@Mark - Try the Modify forum. I'm not too familair with the engines themselves.

 

[cnpalmer]

Hydro-Turf & Head Unit Installs (5.30.09)

Well yesterday was a BIG day! I completed 2 big projects for "Project Sportster"...

First was I finished wiring the head unit and installation of all the power, grounds, RCA's and remote wire. With the amp pushing 4 6.5" Sony 2-ways the system sounds very clean and LOUD! :hurray: I think the addtion of the XTC baffles behind the speakers really help to focus the sound a bit more into the interior and not through the hull.

Second, the Hydro-Turf which had been laying out in my cellar for days was installed to too. Took a few steps for cleaning prep... first vacuumed the entire interior, then used Fantastic to clean away and dirt, dust, smudges etc. Then took acetone and wiped every area to clean away and residue left over. APplied each section of turf, stood on each piece, walked oneach piece and gave as much pressure as I could. Some areas were a little tough but they all came out aligned ok. :hurray:

I have some minor small projects left... clean up wiring and radio switch in engine compartment, support bracket/mount for head unit, clean up of wiring in console...

And then its onto my LED installations. Anyone have any extra stock switches and/or knobs? Those things are mucho $$$ and I wanted to keep the stock switch look when adding in the LED's on the console.

 

[JustinM]

looks very good, I'm waiting to see the LED install, what are you thinking? underwater inside, i was reading some post, and think it is cool to do the cup holders and maby the stereo or comartment boxes.

 

[RFoster130]

Lookin good. Nice boat, especially for what you have in it.

 

[cnpalmer]

@JustinM - I was thinking a couple for the cup holders, 2 behind my console mirrors, a couple in the dash for the guages, and a few strips along the bottom of the seats for floor lighting. Then 2 flood lights under the negine hood. Gonna be a good install and time consuming but based on what I've seen should be worth it.

@RFoster130 - Thanks! I know its a single engine 03 but for what I spent and what I put in it I'm really happy. Still more work left to do but I don;t think it'll ever end.

 

[2001GTXdi]

Looks Good

Looks sharp, although I would recommend a stereo cover ($20 on ebay). It will fry if/when it gets wet.

I'm getting ready to do a stereo on mine and I was looking around for ideas. I hate the stereo under the steering wheel as it kills the leg room. I'm 6'1" and can't sacrifice the space although it is easily reached there. I've seen people put wired remotes in the cup holder too.

Hydro-Turf looks bitchin' too!

Hope to see the lights soon.

 

[cnpalmer]

@2001GTXdi - Thank you for the compliments! I def need a cover, already drenched it once and now the volume knob is a little iffy/touchy. Oh well, live and learn, "marine grade" <> "water-proof"!

The turf is a huge improvement, it hides a lot of blemishes LOL.

I have a wrired remote & 2 more 6.5" speakers to put in. Just not sure where. I was thinking with the other set of speakers to may put them on the back hatch some how, that when when I'm anchored near shore I can switch the stereo to those speakers like an A/B set and hear the stereo even better.

Lights are gonna be on order shortly. After the $$$ I threw in and then some work I need on my tow vehicle (04 Wrangler) I was coming up short for the other stuff i wanted. But all in due time I guess.

I'll def keep it the thread updated as I progress... stay tuned!

 

[cnpalmer]

Weekend updates (7.12.09) - Remote & Antenna

Well seeing how we finally have gotten some decent weekends up here in western MA, I took advantage of a real nice Saturday morning.

I was finally able to finish wiring in my Sony RM-55 remote and a new BOSS Marine Antenna I picked up on eBay for $4.00 (shipping was 2x as much though... of course!).

The antenna works out perfect. I get amazing reception and the pivot capability is perfect for driving, towing or when covering the boat. It's not in the way and easy to reach from the driver's seat.

The remote is also a perfect place since the head unit faces the front of the boat. I guess this the place most people mount their's if they don't mind losing a cup holder, which I didn't at all. I'd rather have the convience than the luxury I suppose.

Here's the pics... let me knwo whatcha think.

 

[seadoo GTS 1993]

Boat looks sick man!

 

[aosh]

Nice mods

Your boat looks great, and your stereo install has me thinking of doing the same to my 02 Challenger. Just curiouse as I have considered all of but one placement for 4 of my speakers. How did you find your install of the speaker under the throtle next to the driver. was it tight getting the speaker in and how did you go about measuring the placement so that you would not get stuck next to the throttle componets???

Did you find a placement for your other 2 speakers........????

Thanks

 

[cnpalmer]

@aosh - Thanks for the compliments! The speakers went in no problem actually. I didn't even think there was anything behind the hull where I put them so I actually got pretty lucky with the placement of them. I cut the holes smaller than they needed to be and just grinded off enough to keep the fit nice and tight. The baffles helped a lot too and made a good seal between the speaker and the figerglass.

Still haven't decided on the other speakers yet. Everyone says it is loud enough with the 4 but I have them and want to use them. Just not sure of the placement and wiring as well, shold I run them as rears or fronts since they would have to be wired with one of the other sets to keep the same load.

 

[aosh]

Thanks for the info.......

I have booked an install with a local company........the installer owes me a favour.... Your project pushed me over the edge... I would do it my self however we are heading up to the lake for 2 weeks and I want it ready to go tomorrow (can't wait).

Plus my wife saw the pics of your kit and asked why ours doesn't look like that...hahahahahaha:agree:

Anyhow, I think you should put the extras as rears....... just makes more sense for the way the boat is laid out for passengers.. I realize you have the amp behind the seats... but it is to bad there wasn't a little more room between the rear seats (under the shoulder rests and the seats),

There isn't a lot of wall space.....I wonder if they could be squeezed under the rear seats where a person's feet would be. Might be to close to floor, causing for them to be sitting in any splashed water, that pools there.

You might have to try and stack them under each rear speaker on the starboard and port side....

I have been combing through other seadoo pics online for ideas....

I am actually going to have my deck installed into the dry box (cabinet) infront of the steering column. I have a USB and Ipod connection. So I plan on running my Ipod extension out to the tac area on the drivers consol so that I can control music and sound with as little deck exposure. Just wondering what you thing.....as I can always move it to a new location if I do not like it.

Thanks for the info........and I gotta say your ride really looks great compared to the before and after a little TLC:coolgleam:

 

[cnpalmer]

Good luck & enjoy!

@aosh - Good luck with the install. Having a pro do it sometimes is the best way to go if you don't have all the materials or tools yourself.

I like the idea of the speakers below the rear seats I would just be scared about hitting the gas tank while cutting into the figerglass. There's not too much water that gets under there really so that doesn't concern me, but the clearance between the tank and mounting surface sure does!

My head unit has a dedictaed input for an ipod as well as an aux input for anything else with the 3mm head phone jack. I was going to try and figure out a way to add in a dedicated mount for something but can't decide where since I took the driver's side cup holder for the wired remote. I'm sure I'll get some idea soon enough.

One tip would be to have yoru installer add in a switch to cut power to the head unit completely. I know myself and others have doen that just to make sure nothing drains the battery while the boat is just sitting trailered/docked somewhere. Mine is right near the battery and I'll be re-locating it to my dash above my stock switches when I pick up an extra stock switch and knob to keep tihngs looking factory/OEM standard.

Post up some pics, I definitely want to see how it turns out!

 

[aosh]

Post install

Sorry for the delay........we have been away since the 31st... where I think I spent half my salary on fuel for the boat...hahahahaha

Here are a couple of pics of the stereo. The deck is a regular car deck that I had mounted in the dry box behind the steering column. I run either the pig tail Ipod jack out of the dry box, or a simple earphone style wire. I have my Ipod mounted on right behind the wheel, as I used double sided velcro to fix it to the boat. This allows ME and no one else (HAHAHA) to control volume and song. Plus I saved on having to buy a Marine deck and didn't suffer with quality of sound. (just can't get any water in the dry box.

I had 4 6.5" Pioneer marine speakers installed, and yes I did add that kill switch for the stereo that is also located in the dry box. There was already a power source in under neather the dry box, so there was no need to run additional power to the battery from the deck.

For only having 4 6.5" it sounds great, even the marine installer was impressed. I think he attributes it to the deck installed.

I am now working on some of the comsetic things, like replacing some of the deck strippings and cleaning out the engine compartment. I am sure we will only have it out 1 or 2 more times. The warm weather in Vancouver starts to disappear in late Sept. hahahaha

here are a few pics....

Anymore mods to yours'

 

[cnpalmer]

A very nice!

@aosh - Nice install meng. Pretty much the same locations I picked. DId you get baffles behind the speakers at or are they just set into the holes?

Like the location of the HU too. Might want to get a wired remote though that way you can still have pseudo-direct access to the unit without opening the dry box. Also a good place to keep an iPod if you have one and the HU has an input for it.

I like!