2001 xstar custom ballast upgrade.

2001 mastercraft x star ballast upgrade. Another ballast system installation. I know wake wakeworld has a lot of post on ballast installs i thought i would share mine with a few pictures of the install. Threw in some old boat pictures and some new pictures since we overhauled the boat. I don't know how to make notes in between pictures on this site to show what angle the pictures were taken at.

We decided to upgrade the ballast for we were having problems with the aerator pumps priming all the time. Sometimes taking up to 20 mins to get the factory sacs to filled. Talk about frustrating. So we decided to install a system like i did a few years back in my centurion elite v.

Here are a list of some of the major componets used for the installation.

4 Reverse pumps from simer bw85p. ~600gph Probably more like 500gph due to friction loss in the suction line and discharge tube.I know these pumps are not ignition protected like jabsco or johnson pumps.

2 750lbs for the rear lockers

1 370lb for ski locker

1 ~1200lbs bow sac for front seating area

Misc 11/2" fittings for suction line and manifold see pictures. I own an irrigation supply company so i have access to a variety of fittings to make this work in such a tight space. See pictures. If you guys are interested in more detail about the fittings i used just post questions.
11/2" thru hull fitting. Had to drink half a bottle of Crown before we drilled the hole. Kind of scary drilling the 11/2" hole.

Notes:
I figure 4 pumps at ~500gph/60= 33gallons per min flow. I figure i ought to be able to fill the sacs in about 12-15 mins ~3100 lbs

My biggest concern is amperage running all four pumps at once. Each pump pulls 10 full load amps thats a total of 40 amps. I think we may have to upgrade the alternator after this is all done.

FYI we started the install yesterday evening hope to finish up today 4/7/12. When i get done i will try to bring this into my CAD and show a good visual of the plumbing of how it works.

Ask questions if you would like or just bash the post all together!