Thanks for all the replys. I did call Kal Kustom and spoke with Scott Pellaton yesterday (Monday). He offered to have a look at the boat if I could get it to Freemont (yeah, right. there goes the summer). Anyway after explaining all the troubleshooting that I'd done so far, Scott thought that it could be either the ballast sac or a breach in the hull caused by a careless factory worker and their screw gun. So equipped with a cold beer and flashlight I went to work on the Fat Sac extraction.
NOTE: I'm always greatful for the wealth of information to be had from reading the discussion boards. I just wish I had read the posts about how you should always wear long pants and gloves when working down in the bildge. Rug Burns, fiberglass rash, anyone?
Anyway, the bag is out and it leaks. In fact it has about 5 leaks. All the leaks were at the end that was of course stuffed up in bow area. Mystery solved...alomost. While squirelling around in the bildge I also noticed a breach in the forward bulkhead (photo).
This was allowing water to pass through from the stern bildge and as we Direct Drive owner know, there's always a bit of water in the bildge from the shaft packing gland. It's usually never enough water to activate the auto bildge but at the end of the day, when the boat goes back on the trailer and in the garage, the bow is low and any water in the center bildge runs North.
As a final test I will run with the Sac out and check the bow area for any other leaks.