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Old     (Jed)      Join Date: Aug 2013       08-22-2013, 11:01 PM Reply   
Before:
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Old     (Jed)      Join Date: Aug 2013       08-22-2013, 11:04 PM Reply   
Before
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Old    Garon Davis (gpd005)      Join Date: May 2013       08-23-2013, 8:58 AM Reply   
Keep us updated! Don't see many of those around!
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 11:04 AM Reply   
Yes, as far as I understand there were less than 20 of these 1997 Hydrodyne Nexstar V-drives built. Its the only year they were built. The company closed its doors that year.

I bought this one in 2007 for $15k. Built the tower, installed perfect pass, stereo and hard tank ballast.

The years have been hard on the boat and the upholstery has failed so its time for a re-do.

I own it outright and can't see taking on payments to buy a newer boat. I'm pretty handy, so I'm gonna make this sucker into the boat I really want.

I'm deep into the project already, I've only just found time to post some pics. Here you go!
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 11:13 AM Reply   
More before pics.
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Old    BLAIR BARHAM (jonblarc7)      Join Date: Jul 2006       08-23-2013, 11:13 AM Reply   
tower matches up perfect.
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 11:16 AM Reply   
Before. Bow.
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 11:31 AM Reply   
I always hated the bow layout, with the fake recliner action and the thin padding on the upholstery. Worse than the bow is the non lounge area. Captains chairs an a rear bench. Really? Lame. We always had the observer seat spun backwards and a cooler along the side to make a wrap around-ish seating. That rear bench is made forward than it needs to be too. It could've been snugged closer to the engine and created more lounge space.
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 11:34 AM Reply   
Before: rear bench area
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 11:37 AM Reply   
Tear down started on July 10.
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 11:38 AM Reply   
Can't figure out why some pice post sideways. Also can't post more than one from my iPhone. Any pointers?
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 11:55 AM Reply   
This is the bench seat back. It's glass an gel, built with the top half of the boat. If I remove it, I can gain a foot of lounge area. There's a big gap between this support and the fore end of the motor.
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Old    Brearly Mason (Brearly_Mason)      Join Date: Nov 2012       08-23-2013, 12:15 PM Reply   
You might also lose side-to-side rigidity.
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 1:11 PM Reply   
Kind of a big decision to start cutting fiberglass out of my boat. Here's what we gain:
Moving the back seat aft 11 inches enlarges the lounge area. This shrinks the compartments a little bit. I enlarged the opening to the slightly smaller compartments by removing the gutter around the sun deck.
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 1:45 PM Reply   
A bunch of the old boat removed. I used a sawzall at theis point, but later found that an angle grinder with a thin cutoff wheel was the best tool for the job. Any toothed recip or circ saw made lots of chippin and splinters.
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 2:19 PM Reply   
More old stuff removed.


Previous exhaust was above the waterline and was really loud at surf speeds, so I ordered a FAE and some other parts to re route the exhaust below the waterline and to the FAE.
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Old    rzap (zap)      Join Date: Jan 2009       08-23-2013, 2:30 PM Reply   
This is cool

I want to bring home an old Response or Echelon, restore it and use it for skiing
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 2:37 PM Reply   
Pulled the gas tank to get some new fitting installed. The new location of the rear bench required some re configuring of the fill and vent hoses so that I can cover it with floor.

In this pic the tank is reinstalled, seam is patched with glass & resin, the. Some bindo is floating the transition from glass seam to old floor.
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 3:22 PM Reply   
Cut the seat bases out of the bow. Prepping for a playpen configuration over some ballast
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 3:25 PM Reply   
The darker red is fiberglass that I added to support perimeter of the playpen floor.
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 3:32 PM Reply   
Aluminum 1/4" 3"x4" rec tube. Cut, welded & powder coated for the rear deck and back bench top support.
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 3:36 PM Reply   
^^ also have trimmed out the rest of the gutter around the rear hatches. Nice wide access to the compartments. It's not installed in this pic, but there's aluminum 1/4" 2x2 angle behind the back and side of te compartment opening.
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 3:58 PM Reply   
3x4 aluminum angle is fitted to catch the bottom of the seat backs and the back of the seat bottoms. Also visible are the vertical supports for the ledge going from floor to gunwal. I welded the center leg to the backer for the tower which made a great improvement to the widdle and shake in the tower. Previous flex in the gunwal allowed the tower to wiggle, now the tower is tied all the way to the floor so it's rock solid!!! Im very pleased with that improvement.
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 4:11 PM Reply   
Building the seat foundations. 3/4" expanded PVC board. Curve profiles were achieved by making multiple relief cuts and then using a heat gun to relax the un-cut side until the desired radius was formed. Then a top plate of 1/2" PVC board was glued and pin nailed to secure the shape. Standard plumbing PVC primer and cement works perfectly

Also visible are the front ballast hard tanks. In compartment behind the observer and in what used to be the walkway to the bow. (The white one gets secured deeper in that compartment)
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Last edited by Jed; 08-23-2013 at 4:14 PM.
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 4:15 PM Reply   
Final seating layout will be much like Supra boats from a couple years ago.
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 4:18 PM Reply   
Seat foundations are all configured. Time to work on the seat backs.
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Old    MICAH HARPER (MICAH_HARPER)      Join Date: Apr 2010       08-23-2013, 4:44 PM Reply   
bro.....this is awesome
Old    Bobby (mastercraf)      Join Date: Jul 2009       08-23-2013, 4:49 PM Reply   
Quote:
Originally Posted by MICAH_HARPER View Post
bro.....this is awesome
I second this!
Old    Delta Force (wakebordr11)      Join Date: May 2001       08-23-2013, 5:27 PM Reply   
I admire your ambition but you won't have me as a believer in cutting out chunks or fiberglass that all worked together to support the hull and bolting in support - it isn't the same. You went from chemical mechanical bond to straight mechanical...
Old    sperbet            08-23-2013, 5:34 PM Reply   
Quote:
Originally Posted by MICAH_HARPER View Post
bro.....this is awesome
this. props! keep the photos coming
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 6:01 PM Reply   
Quote:
Originally Posted by wakebordr11 View Post
I admire your ambition but you won't have me as a believer in cutting out chunks or fiberglass that all worked together to support the hull and bolting in support - it isn't the same. You went from chemical mechanical bond to straight mechanical...
Didn't say it was stronger. Just sayin it's going to improve the usability of the boat while having satisfactory strength to have a good long life span.
Old    Rob Fullerton (Gotmods)      Join Date: Nov 2012       08-23-2013, 6:08 PM Reply   
Nice work. You doing all the foam and vinyl work yourself? That foam gets pricey. Good thread.
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 6:09 PM Reply   
Building the back panel of the back bench seat. Working on the port end inside radius
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 6:16 PM Reply   
Better pic of the front foundations, battery box and stuff
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 6:17 PM Reply   
Dang the rotated pics!!!
Old    Delta Force (wakebordr11)      Join Date: May 2001       08-23-2013, 6:25 PM Reply   
Do you glass in the seat bases? I like the looks of those bad boys for sure! Are you done with this project and just posting all pics? Keep em coming
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 6:29 PM Reply   
Seat bases will assemble like Malibu 2005 ish. Seat bases get carpet and the screw to the floor with brackets

Job isn't done yet. Working on the upholstering now. Sewed my first piece of vinyl yesterday.
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 6:34 PM Reply   
Patterning for seat back panels
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 6:38 PM Reply   
Jigging for a uniform radius
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 6:42 PM Reply   
Most of the plastic structure is assembled.
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 6:45 PM Reply   
Pull it all out to install carpet.
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 6:52 PM Reply   
Carpet on the seat bases.
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 6:58 PM Reply   
Carpet an cup holders!!!
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 7:05 PM Reply   
Behind the drivers seat I built this rear facing seat with back rest. The elevated seat spot adjacent to it will be a carpeted step for entry/exit the boat at the dock. Our lakes have developed picnic docks spots than we frequent.
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Old    Swatguy (xstarrider)      Join Date: Jun 2007       08-23-2013, 7:07 PM Reply   
Holy chit man. Nice work.


Just quick question. Why did you go the hard tank route vs a bag. Would think you could fill up the space more efficiently with a bag.

Again tho crazy skillls
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 7:13 PM Reply   
Cut the foam for the bow. Spending some time figuring out how to pattern the vinyl and make the covers now.
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 7:25 PM Reply   
Quote:
Originally Posted by xstarrider View Post
Just quick question. Why did you go the hard tank route vs a bag. Would think you could fill up the space more efficiently with a bag.
It just happen that there are a couple business near me who roto-mold the holding tanks for boats and RVs. They have stacks of overruns and blems that they sell cheap. I gave about $15 each for the 8 tanks I have installed. I am rearranging the tanks a bit now but once I get everything situated I'll take some pics.

Once they're installed the hard tanks are super easy and worry free. I have a fill and drain pump for each of the three balast zones, and all tanks in each zone are plumbed together. RearRight, RearLeft and front zones.

I will have one sac when all is done, down in the ski locker area which will be plumbed in with the front zone.
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 7:31 PM Reply   
Removed the tower and windshield preparing for the wrap.
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Old     (Jed)      Join Date: Aug 2013       08-23-2013, 7:33 PM Reply   
Removed the rub rail and all the exterior hardware too.
Old    Mike (fozz)      Join Date: Apr 2011       08-23-2013, 8:05 PM Reply   
This is VERY impressive.. What do you do for a living?
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 8:46 PM Reply   
Fireman
Old    Swatguy (xstarrider)      Join Date: Jun 2007       08-23-2013, 8:52 PM Reply   
So in other words refurbing boats is your full time job. BWAHAHAHAHAHAHAHA. Couldn't resist
Old     (Jed)      Join Date: Aug 2013       08-23-2013, 9:00 PM Reply   
Ahhhhhhhhhh. Well played. :-)
Old    Paulh (paulharenberg)      Join Date: Jul 2007       08-23-2013, 9:38 PM Reply   
Didn't even know a vdrive hydrodyne existed. Is it comparable to a 205v, or something completely different. Mad props on your redo of everything.
Old    Rob Fullerton (Gotmods)      Join Date: Nov 2012       08-23-2013, 9:48 PM Reply   
Get a foam saw
Old    8tens (Ben Kerran) (rukie)      Join Date: Jan 2006       08-23-2013, 9:50 PM Reply   
Very cool thread.
Old    Brett Mock (bmock50)      Join Date: Feb 2011       08-24-2013, 12:15 AM Reply   
I'm subscribed!
Old    Jeremiah Long (machloosy)      Join Date: Mar 2013       08-24-2013, 5:44 AM Reply   
Someone else mentioned they were nervous about the structural integrity. I am as well, but the aluminum bracing looks to be well done and hopefully will be a good stand in for the bracing cut out. All that to say, very ambitious and it looks like you have the skill to pull it off. Work looks nice so far!!
Old    rzap (zap)      Join Date: Jan 2009       08-24-2013, 6:17 AM Reply   
Best thread ever
Old    Ron T (Laker1234)      Join Date: Mar 2010       08-24-2013, 6:32 AM Reply   
That's awesome!!! I've redone two boats but never thought about redesigning the seating, The best part is when you do finish you'll have what you want and know exactly what's under the carpet.
Old    "G" (grant_west)      Join Date: Jun 2005       08-24-2013, 6:49 AM Reply   
I love the Idea of just taking somthing and tweaking it into somthing better.
Looks like your well one your way . Good work keep it going.
Old    Curtis Sherbo (csherbo)      Join Date: Jul 2013       08-24-2013, 6:51 AM Reply   
I really admire your work. This is far beyond my skill level, but it sure motivates me to do more.

Keep up the great work, and I can't wait to see the rest of the project.
Old    Baitkiller (baitkiller)      Join Date: Jan 2010       08-24-2013, 6:51 AM Reply   
Crazy ambitious and i admire the persistence and dedication most. Many times people begin projects like this with a grandiose vision and the thing eventually dies under its own weight.
A couple of thoughts:
Did I hear you say you used Bondo to fair the decks? Bondo will do poorly under sopping wet carpet and quickly fail.
You have cut out all the gutters and now have zero deck water management. You had better buy a good shop vacuum and a case of CorrosionX
You may wind up with stress cracking at your brace points due to point loading at that cross member. The full height tabbed in bulkhead does much to resist torsional or twisting loads.
All that said, i am not hating. I have more skills than most and I will admit that I would never finish this project.
Old     (Jed)      Join Date: Aug 2013       08-24-2013, 8:56 AM Reply   
Quote:
Originally Posted by baitkiller View Post
A couple of thoughts:
Did I hear you say you used Bondo to fair the decks? Bondo will do poorly under sopping wet carpet and quickly fail.
You have cut out all the gutters and now have zero deck water management. You had better buy a good shop vacuum and a case of CorrosionX
You may wind up with stress cracking at your brace points due to point loading at that cross member. The full height tabbed in bulkhead does much to resist torsional or twisting loads.
All that said, i am not hating. I have more skills than most and I will admit that I would never finish this project.
The Bondo has two layers of resin over it. I expect it to perform satisfactorily but I'll be keeping an eye on that area of the floor.

Water management. This will be an issue, so I'm going to have to be that guy who tells people to towel off on the swim deck. Not ideal.

Stress cracks are already an problem with this hull. I have contoured every bracket and backer plate to ensure a even pressure across mating surfaces. Despite my precautions, I expect some stress cracks. I'm wrapping the boat with a new graphic so most of the old, or new stress cracks will never be seen
Old     (newwhit)      Join Date: Mar 2007       08-24-2013, 11:52 AM Reply   
i feel like a worthless human being...
Old    BELEZA (beleza)      Join Date: Mar 2010       08-24-2013, 12:10 PM Reply   
What he said ^^^^^^^
Old    J D (jeff_mn)      Join Date: Jul 2009       08-26-2013, 9:42 AM Reply   
This thread is awesome and although I agree with the comments about structural changes - I think you've addressed them as well as you can and are prepared for any fallout..

Love this project.. Great fricking work!
Old    Onthe Creek (onthecreek)      Join Date: Apr 2013       08-26-2013, 10:16 AM Reply   
only time will tell but the topcap that was left in tact isn't much different from what a direct drive would have. the removed support would obviously come into play for the sundeck so while that's a consideration (that appears to have been corrected) there shouldn't be any issues with the hull in general.

hopefully that was epoxy resin on the bondo.

great project!
Old    Johnny (johnny_defacto)      Join Date: Sep 2006       08-26-2013, 10:41 AM Reply   
Quote:
Originally Posted by zap View Post
Best thread ever
I agree. I am super impressed. I am checking this thread hourly to see if there are any updates
Old    Jason@WakeMAKERS (jasonwm)      Join Date: Mar 2009       08-26-2013, 10:42 AM Reply   
Subscribed, can't wait to see this project completed!
Old    Surf Addict (Desi) (phathom)      Join Date: Jun 2013       08-26-2013, 2:10 PM Reply   
Subscribed. I have to see this get finished. We did something like this to our 73 Marlin when I was a kid. Completely redid the layout of the seating area, but nothing as ambitious and we had all the foam and upholstery work done at a shop. Very impressive here.
Old     (Jed)      Join Date: Aug 2013       08-26-2013, 3:04 PM Reply   
Yes. Polyester epoxy resin over the Bondo. Then bilge paint over that in the rear where my water management issue is. Installing the wrap today and tomorrow. Pics will follow.
Old     (Jed)      Join Date: Aug 2013       08-26-2013, 3:18 PM Reply   
Pics of the hard tank balast in rear. 475# each side rear. 385# up front with plans to add 250 more in a sac under the front floor. Just need to figure out how to put better connectors in an old sac that has waterbed style connectors.
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Old     (Jed)      Join Date: Aug 2013       08-26-2013, 3:32 PM Reply   
Ballast configuration is one large thru hull in the bilge that feeds three centrifugal pumps. (2 tsunami 1200 feeding the back tanks an one smaller one feeds the front). Then there's a tsunami 1200 at each balast area for drain. Three 3way switches control the fill drain of the system. Pretty simple and requires zero fiddling with while on the lake. Just flip switches. No bags or hoses to mess with.

With all three zones full and our usual 6-8 adults the boat take a while I get to wakeboard speed. I know don't have a ton of ballast but I don't think I want any more with this motor-hull combo. Prop is acme 543 13x11.5
Old     (Jed)      Join Date: Aug 2013       08-28-2013, 4:10 PM Reply   
Wrap competed today. Picking up the windows from tint this evening
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Old    Detox (bass10after)      Join Date: Feb 2010       08-28-2013, 5:04 PM Reply   
Quote:
Originally Posted by fozz View Post
This is VERY impressive.. What do you do for a living?
Didn't you notice the fire house in the background!??
Great thread and impressive skills to boot!!
Old     (Jed)      Join Date: Aug 2013       08-28-2013, 6:24 PM Reply   
Pleased with the window tint.

The wrap was challenging at times. In impressed with the material and how workable it is. The air release is amazing. The compound curves and sharp angles were a bugger. With the help of a pro (friend of mine) it took us 18 hours to print and install the wrap.

I had completely prepped the boat and created the art ahead of time.
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Old    Brett Yates (polarbill)      Join Date: Jun 2003       08-28-2013, 6:32 PM Reply   
Old    Jeremiah Long (machloosy)      Join Date: Mar 2013       08-29-2013, 5:00 AM Reply   
^^^^ I second this
Old    Jeff Rowland (HygOctaneGraphics)      Join Date: Oct 2011       08-29-2013, 12:15 PM Reply   
probably one of my favorite threads on any boat forum. Cant wait to see that interior!

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