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Repair: Fixing a busted nose
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Sunday, 13 April 2008 09:00

Purpose: Shallow East Coast surf eats jetski noses for breakfast when tricks such as the nose stab, backflip, or re-entry land too steep (aka: lawn dart). Superjet hulls are very weak before they are reinforced and it does not take much to crush the nose in the sand. A couple extra layers of fiberglass is great insurance, and of course is often required.

Recommended for: All Superjet owners interested in shredding some surf.

Difficulty: Not fun. But it can be easily done with a basic understanding of wet layup and attention to detail.

Process:

It will be a several day job to get the nose repaired.

Phase 1:

  1. Pull waterbox, gas tank, battery, pipe, and anything else hindering access to inside front nose area. You want to be able to get your head and shoulders/arms up in this area.
    • Pulling motor will help but maybe not required.
    • Pulling handlepole and controls will help but not required.
  2. Clean up and grind inside front nose area smooth
    • If your nose is hanging, cut it out like this and use some aluminum strapping to secure the two pieces together like this
  3. Lay up 2-3 layers biax, wait for it to cure (could take 24hrs with old or slower resin/hardener or you can pick up a quart of West Systems resin and medium hardener with pumps from a boat store and hope it works quicker.)
Phase 2:
  1. Grind out all cracks from the outside, possibly through to new inner layer. Taper out several inches to minimize hard curves.
  2. Test different types of cloth, biax, mat for best layup
  3. Lay it up
    • Fill very bottom layer with cabosil filler if needed to fill any potential air pockets
    • Build up low spots with mat (i.e. 2", then 4", then 8", etc or whatever is needed and final layer with either mat or cloth or both).
    • May need to split phase to flip the ski and get the bottom of the lip also
Phase 3:
  1. Clean everything up
  2. Break out the body filler - Bondo Fiberglass Resin Jelly
  3. Sand, body filler, repeat until done.
  4. Break out the Bondo glazing compound to fill in any swirl marks left from sanding

Tip: Taylor Curtis or Blowsion makes a replacement nose that works by cutting out the old nose, slipping the new one on, securing it, and glassing it in. This could be a good option if your nose is fubar-ed.
 
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