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Old 22 March 2016, 17:45   #1
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Zodiac ProJet 420 Project

Here is my winter project. 2004 Zodiac ProJet 420. It was left in S. Florida saltwater for 2 months unprotected. Full of barnacles. Tubes falling off.
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Old 22 March 2016, 17:48   #2
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Another
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Old 22 March 2016, 20:38   #3
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New tubes or are you going to try to salvage them? Good luck and lets see progress pics!
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Old 23 March 2016, 00:09   #4
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Trying to salvage tubes. Simple Green and Magic Eraser work wonders. Broken barnacles punched some pinholes in tubes. Just finished gluing one of the bolt ropes on.
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Old 23 March 2016, 00:14   #5
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More pics
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Old 23 March 2016, 00:19   #6
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More progress
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Old 23 March 2016, 00:24   #7
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Compound and polish glass. Started on tubes.
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Old 23 March 2016, 00:27   #8
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Glue bolt rope back on. Tried gel coat forthe first time.
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Old 25 March 2016, 09:45   #9
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TT,

It looks like you have done a very nice job of re-attaching the rope bolt to the tubes.
I fixed the exact same problem myself, on my Zodiac 650 Pro, where the rope bolt glue broke down and separated from the tubes due to the heat, UV and sun here in the Bahamas. I concluded that there just isn't enough surface area the flange of the original rope bolt offers to stay in place in tropical conditions.

My solution was to re-attach it, like you have done, then reinforce it by glueing a 2.5" wide strip of PVC (in my case) on either side of the existing 'flange', top and bottom the entire length of the rope bolt. It now has, effectively, a 5 inch wide additional reinforcement flage holding the whole thing in place. I managed to procure the new PVC sheet material from a bespoke RIB maker in the UK and brought it with me on the flight in my checked baggage!!

Importantly, I was able to get hold of the correct 2-part PolyMarine PVC adhesive from West Marine in Florida which, hopefully, will hold everthing together for the foreseeable.

I've used my RIB in some very choppy seas and, after a year, it's still holding together. Just thought I'd pass this along in case you feel it could help.
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Old 25 March 2016, 14:15   #10
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Looking good!
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Old 25 March 2016, 18:19   #11
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Good job.

Generally surprised you got the steering wheel off. Thought it would be siezed on solid.
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Old 25 March 2016, 23:41   #12
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Glued last bolt rope on. Patched pin holes in tubes. Had some time to burn and decided to try to start tHe engine. Turned the key and nothing. Put in a new battery still nothing. Took apart the control box and jumped the starter solenoid and still nothing. Does anyone know how to get to the starter?

Binty, this boat lived in Nassau for a while. Sounds like your reinforcing tape idea should work.
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Old 26 March 2016, 10:47   #13
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Binty, this boat lived in Nassau for a while. Sounds like your reinforcing tape idea should work.
Small world!
As a matter of interest, my first repair was to just re-attach the rope bolt (after hours of meticulously cleaning and prepping the mating surfaces)...put it all back only to experience the joint's failure after one week's use

The overlapped re-inforcing tape was only added at the second attempt...and it's held firm ever since. It's much stronger that the original and I can't figure out why Zodiac didn't do this at the manufacturing stage. Anyway, good luck with your refurb and looking forward to more pics and a running report when you get it back in the water.

I feel I could write a book on this subject from tips and tricks of removing tube sets to re-installing them (always a struggle, even with two srong men) to plugging minor air leaks and so on.
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Old 26 March 2016, 11:11   #14
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Glued PVC in general does not hold up well in warmer climates such as Florida and the Bahamas. Up here in New England I have seen tubes that are twenty years old and the bond on the bolt rope tube is still in perfect shape. The other big factor is proper inflation. Most people do not properly inflate their tubes and confirm with a pressure gauge. Under inflation will allow movement of the tubes which adds a lot of stress to that joint.

Good luck in the jet project. Getting the drive unit cleaned up after being in salt water for two months may be a challenge. However, if you get it running right it will be a blast. I've had a few of those Projets and they are a lot of fun.
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Old 26 March 2016, 15:27   #15
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Yamaha 760cc 80hp twin two strokes in these..? Not a lot I don't know about these, I've rebuilt 6 or 7 over the years and run one weekly.

Happy to help..
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Old 26 March 2016, 15:32   #16
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Starter is located opposite side to the carbs, under the exhaust manifold. Positive feed is on top of the starter and case is the earth. Always run a second earth from battery negative to motor cases.

Items that tend to fail in this area are bendix, starter and positive / negative leads.

I'd be astonished if the pump isn't seized - the wear ring expands due to salt corrosion pressing the liner against the prop blades - this will need stripping and a new liner installing by a machine / Jetski shop. If this is indeed seized, the engine won't turn over - pull the pump, it's only 8x bolts and try again - your starter may well be fine.

All the running gear is based on a Yamaha Superjet by the way

Jim
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Old 26 March 2016, 22:27   #17
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Quote:
Originally Posted by Binty_Bexter View Post
Small world!
As a matter of interest, my first repair was to just re-attach the rope bolt (after hours of meticulously cleaning and prepping the mating surfaces)...put it all back only to experience the joint's failure after one week's use

The overlapped re-inforcing tape was only added at the second attempt...and it's held firm ever since. It's much stronger that the original and I can't figure out why Zodiac didn't do this at the manufacturing stage. Anyway, good luck with your refurb and looking forward to more pics and a running report when you get it back in the water.

I feel I could write a book on this subject from tips and tricks of removing tube sets to re-installing them (always a struggle, even with two srong men) to plugging minor air leaks and so on.
Only a week? Sounds like glue failure to me. Most people put too much on. Combined with some moisture and a short cure time, it's a recipe for disaster.
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Old 27 March 2016, 01:36   #18
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Thanks for the info guys. I did take the pump apart on the first part of the rebuild. The impeller spins fine in the housing. I have had this replaced before. This is the Yamaha 2 stroke 80 hp engine. I ended up pulling the motor to find the positive and negative battery cables bad. Made some new cables and going to put engine back in tonight. I did run some jumper cables directly to the starter just to be sure the starter was good. Cranked fine. It is sure nice to have a nice shop / garage with an electric hoist. Makes the job a little easier.

I borrowed an awesome wheel puller from my maintenance guys at work. Took the steering wheel hub right off.
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Old 27 March 2016, 01:39   #19
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Engine out
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Old 27 March 2016, 09:50   #20
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Ah ha! The culprit.
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