tag:blogger.com,1999:blog-12791938068600561802024-03-18T19:53:53.362-07:00Centurion Avalanche Ballast InstallSteve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.comBlogger15125tag:blogger.com,1999:blog-1279193806860056180.post-50904086791919635312009-09-19T13:41:00.000-07:002010-11-14T21:33:24.643-08:00The Ballast Dream...The purpose of this blog is to create a place to compile all of the information and pictures that I have from designing and building my ballast system. Hopefully this will allow all this information to be just a "click" away for my boating friends or those just wanting to build a ballast system. I realize there are many ways to build a great system. This just happens to be the way I did it. I'm not saying its the greatest way but it turned to be just as awesome as I dreamed it to be!<br />
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This ballast system is for a 2003 Centurion Avalanche. The ballast system will be used primarily to create a surfing wave on the port side of the boat. However this particular set up can be easily modified to design a ballast system for the starboard side of the boat or for a more equally balanced ballast system for <span class="blsp-spelling-error" id="SPELLING_ERROR_0">wakeboarding</span>. The boat currently has no factory ballast system so I am basically starting from scratch on this one. If your boat has some hard tanks already installed the process can be much easier<br />
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My current surfing set up includes using 4 fat sac’s that I manually fill with pumps that are powered from the 12 volt accessory outlet. The current sac’s are 750# in port locker, 500# on rear seat toward port side, 175# under port seats, and 175# on port seats for a total of 1600#. It takes about 20 minutes to fill all these bags and other 20 minutes to empty them.<br />
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The new automated system will fill the new sacs with a push of 2 buttons on the switch panel and should both fill and empty in less than 10 minutes. The new system will utilize a custom made Flying High Pro X fat sac that is designed to completely fill the entire port locker and then continue forward under the port seats. The dimension and weight of the custom sac is as follows:<br />
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Main 22H X 24W X 52L<br />
Arm 10H X 24W X 62L<br />
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Main… <span class="blsp-spelling-error" id="SPELLING_ERROR_1">LXWXH</span> = 27456 = 118.857 gallons = 992.46 pounds<br />
Arm.. <span class="blsp-spelling-error" id="SPELLING_ERROR_2">LXWXH</span> = 14880 = 64.416 gallons = 537.87 pounds<br />
Total cubic inches = 42336 = 183.272 gallons = 1530 pounds<br />
*Water 8.35 pounds per gallon<br />
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I am using 2 reversible Johnson Ultra Ballast pumps (13.7 <span class="blsp-spelling-error" id="SPELLING_ERROR_3">GPM</span>) to both fill and empty the custom sac. I chose these pumps over the <span class="blsp-spelling-error" id="SPELLING_ERROR_4">Jabsco</span> Ballast Puppy pumps that flow at only 9 <span class="blsp-spelling-error" id="SPELLING_ERROR_5">GPM</span>. The advantage (which is controversial by those that prefer the aerator type pumps) of the reversible pump is that you can use the same hole in the bottom of the boat to both fill and drain the sacs. This means less holes in the boat!<br />
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There are many arguments over using an impeller type pump vs a aerator type. The aerators are cheaper, quieter, and draw less power. The impeller type are more heavy duty but noisier and draw a lot of power. If you want help choosing which is best for you, read this ballast thread... <a href="http://www.centurioncrew.com/Aerator-Pumps-and-Electric-t1970.html">http://www.centurioncrew.com/Aerator-Pumps-and-Electric-t1970.html</a><br />
This guy tests out the most common type of pump and incorporates different valves as well to see how they effect flow. Some really great hard core info here on pump and valve performance. This data came out after my install was done. I am glad I chose the Johnson pumps and did not utilize any sprinkler valves in the system. <br />
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For my water intake, I am using a 1 ¼ inch <span class="blsp-spelling-error" id="SPELLING_ERROR_6">thru</span>-hull scupper (brass) that will be installed in the bottom of the boat near the speed wheel and T handle floor drain. The 1 ¼ inch inlet/outlet should be sufficient to allow two 1” lines to be run (one to each pump) and allow the pumps plenty of water flow as to not be starved for water. The pumps themselves only have a 1/2” inlets/outlets and the fat sacs only have ¾ inch drain/fill holes. So there are other natural bottlenecks in the system other than the intake.<br />
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This ballast system will have two auxiliary fill hoses that will allow other auxiliary sacs to be filled when needed/wanted. These sacs can be placed on the rear seat, port seat, walk through, bow area, or floor area as needed. The two hoses can be pulled out of a compartment to fill/drain the aux sac and then disconnected from the sac and stowed in the compartment.<br />
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The custom sac will also have a vent/overflow drain. This will be connected by hose to a 1” stainless steel <span class="blsp-spelling-error" id="SPELLING_ERROR_7">thru</span>-hull vent on the port side of the boat and will utilize a one way (spring type) valve <span class="blsp-spelling-error" id="SPELLING_ERROR_8">inline</span> to prevent water from entering into the sac from lake. Once the sac is full this will overflow indicating that the pumps need to be turned off. This will also allow any excess air in the sac to be “burped” off. When emptying the sac the one way valve will not allow any air into the sac and it should raisin up as it drains which is nice to preserve storage space.<br />
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Schematic drawing of ballast system as well as an itemized list of plumbing supplies and their location in addition to how many of each are needed. *The sac’s are not to size or shape*.<br />
Double click on any photo to enlarge it.<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRAnYz-KWL6M9WfzZMMRuKCZNLwnKBhdUlGqLPFJwsHuwqsX3g2Ntr-lv-uUbHwUQjyxqJacam8GJZji7ik6wJZILDIAWE_VCYtyRGcVts4StIXSqGChldEJPwKuC1xphTFUASQfYNUmcI/s1600-h/ballast+system+mod+%5B640x480%5D.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383285615461491634" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRAnYz-KWL6M9WfzZMMRuKCZNLwnKBhdUlGqLPFJwsHuwqsX3g2Ntr-lv-uUbHwUQjyxqJacam8GJZji7ik6wJZILDIAWE_VCYtyRGcVts4StIXSqGChldEJPwKuC1xphTFUASQfYNUmcI/s320/ballast+system+mod+%5B640x480%5D.jpg" style="cursor: hand; float: left; height: 320px; margin: 0px 10px 10px 0px; width: 239px;" /></a><br />
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Drawing of the Custom <span class="blsp-spelling-error" id="SPELLING_ERROR_9">Avy</span> sac used to place the order<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzPAqTRAb9NYuTwgRPMfTRh0CQYIV7AC0ui2mAqOlkB_-f2qrpTl5vMh2fha12RIClBAz0PSAVKTa4Gy7sFijQ2VmZkF9vfhyphenhyphenWba3weyDklqofoHe6S4b7IN3v_aVUiq0DMOG-pzZcjHXL/s1600-h/ballast+sac+modified+%5B640x480%5D.jpg"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383285623683064434" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzPAqTRAb9NYuTwgRPMfTRh0CQYIV7AC0ui2mAqOlkB_-f2qrpTl5vMh2fha12RIClBAz0PSAVKTa4Gy7sFijQ2VmZkF9vfhyphenhyphenWba3weyDklqofoHe6S4b7IN3v_aVUiq0DMOG-pzZcjHXL/s320/ballast+sac+modified+%5B640x480%5D.jpg" style="cursor: hand; float: left; height: 214px; margin: 0px 10px 10px 0px; width: 320px;" /></a><br />
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Picture of the custom <span class="blsp-spelling-error" id="SPELLING_ERROR_10">Avy</span> sac blown up with air. Its HUGE!!!<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGZWRPs7LK3JZaFPSiZldu83ATZfNZ0aq5OYMvqdAv-YR9i9ZDPxLUoTA3NZ_VFVEkOBoGSvRhtnGOWyLgqa_oOcJ8lRDPlHn426pj1Ve5mmH52Z_r6HYdk4eO8071dnnypEkmnkJ3hcnU/s1600-h/Custom+sac+2+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383285633194185826" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGZWRPs7LK3JZaFPSiZldu83ATZfNZ0aq5OYMvqdAv-YR9i9ZDPxLUoTA3NZ_VFVEkOBoGSvRhtnGOWyLgqa_oOcJ8lRDPlHn426pj1Ve5mmH52Z_r6HYdk4eO8071dnnypEkmnkJ3hcnU/s320/Custom+sac+2+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 240px; margin: 0px 10px 10px 0px; width: 320px;" /></a>Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com1tag:blogger.com,1999:blog-1279193806860056180.post-87684404909359791522009-09-18T14:31:00.000-07:002009-09-19T22:28:35.294-07:00Supply list<strong>Plumbing</strong><br />1 - 1 ¼” bronze <span id="SPELLING_ERROR_0" class="blsp-spelling-error">thru</span>-hull scupper (West Marine)<br />1 – 1 ¼” brass ball valve (<span id="SPELLING_ERROR_1" class="blsp-spelling-error">Lowes</span>)<br />1 – 1 ¼” PVC threaded to slip adapter (Home Depot)<br />1 – 1 ¼” piece of PVC (about 1 foot) (Home Depot)<br />1 – 1 ¼” PVC “T” (all slip connections) (Home Depot)<br />2 - PVC 1 ¼” slip to 1” thread adapter (Home Depot)<br />12 – 1” PVC threaded to hose barb (<span id="SPELLING_ERROR_2" class="blsp-spelling-error">HB</span>) adapter (Home Depot)<br />40 feet multi-flex 1” I.D. hose (<span id="SPELLING_ERROR_3" class="blsp-spelling-error">Evco</span> House of Hose) Used 090-1 hose<br />2 – Johnson Ultra Ballast reversible pumps (13.7 <span id="SPELLING_ERROR_4" class="blsp-spelling-error">GPM</span>) (<span id="SPELLING_ERROR_5" class="blsp-spelling-error">maxwake</span>.com)<br />2 – 1” “T” hose barb <span id="SPELLING_ERROR_6" class="blsp-spelling-corrected">connector</span> (Home Depot)<br />4 – 1” PVC ball valve (threaded) (Home Depot)<br />3 – Flying High Flow-rite quick connect elbow (W746) (<span id="SPELLING_ERROR_7" class="blsp-spelling-error">maxwake</span>.com)<br />3 – Flying High Flow-rite quick connect sac valve threads (W743) (<span id="SPELLING_ERROR_8" class="blsp-spelling-error">maxwake</span>.com)<br />1 – Launch Pad “link” connector (Ordered from Launch Pad)<br />1 – 1” hose barb to male garden hose adapter (Home Depot)<br />1 – Blue magic perfect union water bed connector (purchased online)<br />1 - 1” <span id="SPELLING_ERROR_9" class="blsp-spelling-error">inline</span> check valve (spring type) threaded. (<span id="SPELLING_ERROR_10" class="blsp-spelling-error">Lowes</span>)<br />1 – 1” stainless steel <span id="SPELLING_ERROR_11" class="blsp-spelling-error">thru</span>-hull side discharge (West Marine)<br />30 – stainless steel hose clamps (3/4” to 1 ¾” size) (Home Depot)<br />4 – 1” PVC 90 degree elbow hose barb connectors (Home Depot)<br /><br /><strong>Electrical </strong><br />4 - 10 gauge wire, 8 feet long, all different colors (Home Depot)<br />1 - 10 gauge wire, 5 feet long, black (Home Depot)<br />2 - mini fuses, 25 amp (Checker Auto)<br />6 – butt splice connectors for 10 gauge wire (Home Depot)<br />10 – insulated female push on connectors for 10 gauge wire (Home Depot)<br />1 – 20 feet split loom plastic electrical conduit (Home Depot)<br />3 – rolls electrical tape (Home Depot)<br />1- can of liquid electrical tape (Home Depot)<br />10 – 8” zip ties (Home Depot)<br />10 – 8” mounting zip ties (Home Depot)<br />8 – ½” long (size 10) stainless steel screws (for mounting zip ties) (Home Depot)<br /><br /><strong>Other supplies</strong><br />Painters masking tape 1 roll (Home Depot)<br />Black sharpie pen<br />1 5/8” hole saw (Home Depot)<br />1 ¼ “ hole saw (Home Depot)<br />Safety glasses (Home Depot)<br />Dust mask (Home Depot)<br />Rotary sander drill bit or <span id="SPELLING_ERROR_12" class="blsp-spelling-error">dremel</span> tool<br />Shop vac<br />Razor knife<br />Heat gun (Home Depot)<br />Bench vise (Home Depot)<br />¾” cheep paint brush<br />Small paper cup<br />Dish soap<br />Screwdrivers<br />Hex screw driver for hose clamps<br />Acetone (home depot)<br />Marine sealant 3M 5200 fast cure 1 tube (home depot)<br />Rags for clean up<br />PVC cement (Home Depot)<br />Hack saw (Home Depot)<br />PVC cutter (Home Depot)<br />Teflon pipe thread tape (2 rolls)<br />4 – size 8, 1/2” flat head stainless steel screw (for <span id="SPELLING_ERROR_13" class="blsp-spelling-error">thru</span>-hull scupper) (Home Depot)<br />8 – size 12, 1 ½” pan head stainless steel screws (for pump mounting) (Home Depot)<br />24 – ½ inch stainless steel washers (spacers so pump screws don’t go through wall) (Home Depot)<br />2 - dash switches, double position/double throw (<span id="SPELLING_ERROR_14" class="blsp-spelling-error">DPDT</span>) (ordered from Centurion)<br /><br />I listed the places I bought items from or ordered them from online. There are many great vendors out there for many of the items. Search around for good prices and use whoever you would like. Since doing this install I have found Wakeoutlaws to be a great place to shop and they are great supporters of Centurion boats. <a href="http://www.wakeoutlaws.com/">http://www.wakeoutlaws.com/</a>Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com0tag:blogger.com,1999:blog-1279193806860056180.post-46608314286848135632009-09-17T14:35:00.000-07:002009-09-19T22:29:37.642-07:00Hole in the boat #1!!! Installing the side ventThis is probably the hardest part of the project. Boats are not meant to have any holes in them. Holes make boats sink. Get over it! Some say that a couple beers make this easier but I am not sure how straight it makes your holes!<br /><br />You need to decide where to put your side dump hole. Check it out from both the outside for cosmetics and the inside for adequate spacing and access. If you already have a bilge outlet you can use it for reference.<br /><br />I used a 1 inch stainless steel <span id="SPELLING_ERROR_0" class="blsp-spelling-error">thru</span>-hull side dump that I purchased at west marine. On the inside it has a hose barb for 1” ID hose. I had several size hole saws and I cut some test holes in a piece of wood to see what size was the tightest fit. The 1 ¼” hole saw was a very tight (too tight) fit but I chose it because the next size up was too big. After drilling the hole I used the rotary sander bit to make the hole just a <span id="SPELLING_ERROR_1" class="blsp-spelling-error">smidge</span> bigger. More on that later….<br /><br />So once you have chosen your hole location and hole saw size, mask off the area with painters tape and mark it with a sharpie. Put on safety glasses and dust mask. Make sure you have adequate clearance on the inside for when the drill bit breaks through. Begin drilling with the hole saw in reverse and continue in reverse until well through the gel coat and into the fiberglass. This is to prevent the hole saw from binding or grabbing and cracking or <span id="SPELLING_ERROR_2" class="blsp-spelling-error">spidering</span> your gel coat. Don't press too hard. You can finish drilling the rest of the hull either in forward or reverse.<br /><br />Once the hole is made use the rotary sander to radius (not sure if this is the correct term) the edge of the hole where the gel coat is. Essentially sand the gel coat edge back so it’s a small rounded edge with no sharp transition to prevent any future cracking/<span id="SPELLING_ERROR_3" class="blsp-spelling-error">spidering</span> of the gel coat. Try the <span id="SPELLING_ERROR_4" class="blsp-spelling-error">thru</span> hull fitting for size and rotary sand the hole if needed to get a good fit.<br /><br />On the inside use a razor knife to trim the carpet well away from the hole to allow room for the nut to secure the fitting.<br /><br />Once finished use a shop vac for clean up. Clean the new hole with acetone to prep for sealing with marine sealant. Coat the back edge of the <span id="SPELLING_ERROR_5" class="blsp-spelling-error">thru</span>-hull and some of the threads with the 3M 5200 marine sealant and seat in hole. On the inside put more sealant on to fill any gaps in the hole. Thread on the mounting nut and tighten. Wipe any excess sealant away and clean any remaining extra with acetone.<br /><br />Masked and marked ready for drilling<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_7Rm95b8BZzP3oJYYoAEg3A405fWOllamoBPgHlN3wpLlH2wH0gjQbyZsuwqRFV6BJyWH1LTUXAedCPQXy5itCdgud82YnFkPxizV-kBrG-dEJrE4Z_mJDbt5TUUgnoNg_cgN7VwgmY9S/s1600-h/side+hole+prep+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383297219417029154" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_7Rm95b8BZzP3oJYYoAEg3A405fWOllamoBPgHlN3wpLlH2wH0gjQbyZsuwqRFV6BJyWH1LTUXAedCPQXy5itCdgud82YnFkPxizV-kBrG-dEJrE4Z_mJDbt5TUUgnoNg_cgN7VwgmY9S/s320/side+hole+prep+%5B640x480%5D.JPG" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_7Rm95b8BZzP3oJYYoAEg3A405fWOllamoBPgHlN3wpLlH2wH0gjQbyZsuwqRFV6BJyWH1LTUXAedCPQXy5itCdgud82YnFkPxizV-kBrG-dEJrE4Z_mJDbt5TUUgnoNg_cgN7VwgmY9S/s1600-h/side+hole+prep+%5B640x480%5D.JPG"></a><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br />The first hole with edges <span id="SPELLING_ERROR_6" class="blsp-spelling-error">radiused</span><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0qr07fLDQEGNiZ7Iy9YmsrKemzbqpbsTthqdXqPfcne0h4P92DRYlmupNK2KlpExwBuX4Wi2RwDaDqsgCPe2_HIJqFi1Y3aRhr7zdB3TRomKjJEyc5cjB4TM6Bs8A122N2mWVsAl-6Qon/s1600-h/side+hole+finished+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383297222283809218" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0qr07fLDQEGNiZ7Iy9YmsrKemzbqpbsTthqdXqPfcne0h4P92DRYlmupNK2KlpExwBuX4Wi2RwDaDqsgCPe2_HIJqFi1Y3aRhr7zdB3TRomKjJEyc5cjB4TM6Bs8A122N2mWVsAl-6Qon/s320/side+hole+finished+%5B640x480%5D.JPG" /></a><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br />The hole from the inside with carpet cut back<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuyeu6Fd-zKvffZuKlEAh2DaSiRs-saF0jS6wdju6AIPsKYgCUZ4gqUoGsep82dT1iA5pocFromyL6XPb0FmDDE43zItFbJoEjyFZLLTckPVaw5EjYg7HwM6ehrcpiDhdKSWF33FQcIDQR/s1600-h/side+hole+inside+with+nut+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383297233602537794" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuyeu6Fd-zKvffZuKlEAh2DaSiRs-saF0jS6wdju6AIPsKYgCUZ4gqUoGsep82dT1iA5pocFromyL6XPb0FmDDE43zItFbJoEjyFZLLTckPVaw5EjYg7HwM6ehrcpiDhdKSWF33FQcIDQR/s320/side+hole+inside+with+nut+%5B640x480%5D.JPG" /></a><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br />The drill bit sander used to radius the edge and enlarge the hole<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3xLejONAdkZv9WUuXsSK-Bi5ctoHu-xwekf67nNCOWyBDi8HG9-YxOI1ffS3ywcfU2mAu6Hpyq7arANO6attI5LEi6gBTzap-Bj3C8Z2epLnCnoqSUsCkqwIDcNItK8_FYc1SoY-QRssY/s1600-h/rotery+sander+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383297242399112978" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3xLejONAdkZv9WUuXsSK-Bi5ctoHu-xwekf67nNCOWyBDi8HG9-YxOI1ffS3ywcfU2mAu6Hpyq7arANO6attI5LEi6gBTzap-Bj3C8Z2epLnCnoqSUsCkqwIDcNItK8_FYc1SoY-QRssY/s320/rotery+sander+%5B640x480%5D.JPG" /></a><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br />The <span id="SPELLING_ERROR_7" class="blsp-spelling-error">thru</span>-hull in place<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiDXKE__7dGXJAi-WLe1sblsqIi7JrpiCWHW1f-E9h1LjfUCl5J-MA5CwOMI_z5uQCgNWWOoGaDBt7DRqCRjo_p1Fdfg3U75tTV1IfyWouiLTlLk_ueetxRtPsQSae6THpR-vs2gQwxBzM/s1600-h/side+thru-hole+installed+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383297247656642242" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiDXKE__7dGXJAi-WLe1sblsqIi7JrpiCWHW1f-E9h1LjfUCl5J-MA5CwOMI_z5uQCgNWWOoGaDBt7DRqCRjo_p1Fdfg3U75tTV1IfyWouiLTlLk_ueetxRtPsQSae6THpR-vs2gQwxBzM/s320/side+thru-hole+installed+%5B640x480%5D.JPG" /></a><br /><br /><br /><br /><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3xLejONAdkZv9WUuXsSK-Bi5ctoHu-xwekf67nNCOWyBDi8HG9-YxOI1ffS3ywcfU2mAu6Hpyq7arANO6attI5LEi6gBTzap-Bj3C8Z2epLnCnoqSUsCkqwIDcNItK8_FYc1SoY-QRssY/s1600-h/rotery+sander+%5B640x480%5D.JPG"></a><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0qr07fLDQEGNiZ7Iy9YmsrKemzbqpbsTthqdXqPfcne0h4P92DRYlmupNK2KlpExwBuX4Wi2RwDaDqsgCPe2_HIJqFi1Y3aRhr7zdB3TRomKjJEyc5cjB4TM6Bs8A122N2mWVsAl-6Qon/s1600-h/side+hole+finished+%5B640x480%5D.JPG"></a><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_7Rm95b8BZzP3oJYYoAEg3A405fWOllamoBPgHlN3wpLlH2wH0gjQbyZsuwqRFV6BJyWH1LTUXAedCPQXy5itCdgud82YnFkPxizV-kBrG-dEJrE4Z_mJDbt5TUUgnoNg_cgN7VwgmY9S/s1600-h/side+hole+prep+%5B640x480%5D.JPG"></a><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuyeu6Fd-zKvffZuKlEAh2DaSiRs-saF0jS6wdju6AIPsKYgCUZ4gqUoGsep82dT1iA5pocFromyL6XPb0FmDDE43zItFbJoEjyFZLLTckPVaw5EjYg7HwM6ehrcpiDhdKSWF33FQcIDQR/s1600-h/side+hole+inside+with+nut+%5B640x480%5D.JPG"></a><br /><br />From the inside with nut in place<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOfEz6mxaC6tPtSn0_0heZivOn5Eyh5RnlOMe5JctzypQWuHbB8xphpcMbU71CGezey0StO1_aB5AxBQ6bb-sw4w7bsGi4oICnJCMhTMDwFL1QZmY3R05OdPpAk2RpxbgfB8D6r-7CG5VK/s1600-h/side+thru-hull+installed+inside+close+up+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383296311226027810" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOfEz6mxaC6tPtSn0_0heZivOn5Eyh5RnlOMe5JctzypQWuHbB8xphpcMbU71CGezey0StO1_aB5AxBQ6bb-sw4w7bsGi4oICnJCMhTMDwFL1QZmY3R05OdPpAk2RpxbgfB8D6r-7CG5VK/s320/side+thru-hull+installed+inside+close+up+%5B640x480%5D.JPG" /></a><br /><br /><br /><br /><br /><br /><div></div>Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com0tag:blogger.com,1999:blog-1279193806860056180.post-44134716020400435702009-09-16T15:02:00.000-07:002009-09-19T22:30:21.347-07:00Hole in the boat #2.... Installing the thru-hull scupperYou need to decide where to put your bottom thru-hull scooper. Check it out from both the outside for cosmetics and the inside for adequate spacing and access. The brass fitting on the outside is rather large. Make sure it is located where it will have access to turbulent free water to prevent any air bubbles from entering the ballast system. You also do not want it to interfere with water flow to your speed wheel, engine water intake, or cause turbulence under the depth finder.<br /><br />I used a 1 ¼” bronze thru-hull scupper/strainer that I purchased at west marine. The hole saw that gave the best fit was a 1 5/8” size. So once you have chosen your hole location, mask off the area with painters tape and mark it with a sharpie. Put on safety glasses and dust mask and begin drilling with the hole saw in reverse and continue in reverse until well through the gel coat and into the fiberglass. This is to prevent the hole saw from binding or grabbing and cracking or spidering your gel coat. Drill through the hull. Once the hole is made use the rotary sander to radius (not sure if this is the correct term) the edge of the hole where the gel coat is. Essentially sand the gel coat edge back so it’s a small rounded edge with no sharp transition to prevent any future cracking/spidering of the gel coat. Try the thru hull scupper in for size and for a flush fit. Use the rotary sander if necessary to custom fit.<br /><br />Use a shop vac for clean up. Clean the new hole with acetone to prep for sealing with marine sealant. Coat the back edge of the thru-hull and some of the threads with the 3M 5200 marine sealant and seat in hole. Use the ½” long size 8 stainless steel screws to mount the strainer edges (drill pilot hole first but don’t go thru the hull). I also put some sealant in the screw holes even though they do not go all the way through. Wipe up any excess sealant. Clean with acetone. On the inside put more sealant on to fill any gaps in the hole. Thread on the mounting nut and tighten. I left all the extra sealant around the inside nut to make sure I had a good waterproof seal since it is below water line. Let it cure overnight before next step.<br /><br />Prepped for drilling with a black dot as my center mark<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJFmc4f56R7O1XbBBIwHzal6f2LmtpgQKtXIzm-vVZJU7sPxVUMdOQqOCu3uB1ZSjcEw4Zq1AuAKJ-WYg5TJmqrNkJlr7UnjAYyvSttTnit0mIgMZAGZr21O9EyNoAKV1EhBoqjUrMpsCZ/s1600-h/Bottom+scupper+prep+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383308552390877618" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJFmc4f56R7O1XbBBIwHzal6f2LmtpgQKtXIzm-vVZJU7sPxVUMdOQqOCu3uB1ZSjcEw4Zq1AuAKJ-WYg5TJmqrNkJlr7UnjAYyvSttTnit0mIgMZAGZr21O9EyNoAKV1EhBoqjUrMpsCZ/s320/Bottom+scupper+prep+%5B640x480%5D.JPG" /></a><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br />This is one big hole. It would sink the boat in no time at all<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT7Y_NOCVk53u3Yuug8JQWEmAJ9WKIAH-FNfDSbQMx-IW85UP6N3wEJ2m3BQI8QVDw-cis3n9cvvSqukQDrQo7KbDTYW5_knkLhDc1rKSGhUfjES20U1fF5uYyJ1HeGa0vuFF2r5wDI3Om/s1600-h/bottom+scupper+hole+(2)+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383308557622153794" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT7Y_NOCVk53u3Yuug8JQWEmAJ9WKIAH-FNfDSbQMx-IW85UP6N3wEJ2m3BQI8QVDw-cis3n9cvvSqukQDrQo7KbDTYW5_knkLhDc1rKSGhUfjES20U1fF5uYyJ1HeGa0vuFF2r5wDI3Om/s320/bottom+scupper+hole+(2)+%5B640x480%5D.JPG" /></a><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br />The hole from the inside (left side of picture)<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRosWMhqz3mPXDwn89kXELtW7gkwl-zHVIeOUnnMe04xhNOm4cQIaOoJE6hhHoaHV3Q_rqQE80g7xJ6gG83CIAJoJhDVighE-AR9bNGa-3LN8ZxKqEyPjgabMrrQ2J9a4KEWrgL2pxSve2/s1600-h/bottom+scupper+hole+inside+3.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383308570369815442" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRosWMhqz3mPXDwn89kXELtW7gkwl-zHVIeOUnnMe04xhNOm4cQIaOoJE6hhHoaHV3Q_rqQE80g7xJ6gG83CIAJoJhDVighE-AR9bNGa-3LN8ZxKqEyPjgabMrrQ2J9a4KEWrgL2pxSve2/s320/bottom+scupper+hole+inside+3.JPG" /></a><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2wpvQlU54qEVWeGY8hb8JHdufc53ymKWhn_D51PDTjsiODP4bUf7IjzVebaJh5RfbMz8DkARDXgs730QmaYtttRHXSoLXYHzu4IFururdHYVIuUrVkKKKo8Ac0VoKVCZ9vRhiCawygtrs/s1600-h/thru-hull+scupper+sealant+%5B640x480%5D.JPG"></a><br /><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT7Y_NOCVk53u3Yuug8JQWEmAJ9WKIAH-FNfDSbQMx-IW85UP6N3wEJ2m3BQI8QVDw-cis3n9cvvSqukQDrQo7KbDTYW5_knkLhDc1rKSGhUfjES20U1fF5uYyJ1HeGa0vuFF2r5wDI3Om/s1600-h/bottom+scupper+hole+(2)+%5B640x480%5D.JPG"></a><br /><br /><br /><br /><br /><br /><br /><br /><br /><br />Sealant on the surface to be mounted (this is way too much BTW)<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2wpvQlU54qEVWeGY8hb8JHdufc53ymKWhn_D51PDTjsiODP4bUf7IjzVebaJh5RfbMz8DkARDXgs730QmaYtttRHXSoLXYHzu4IFururdHYVIuUrVkKKKo8Ac0VoKVCZ9vRhiCawygtrs/s1600-h/thru-hull+scupper+sealant+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383308576959976706" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2wpvQlU54qEVWeGY8hb8JHdufc53ymKWhn_D51PDTjsiODP4bUf7IjzVebaJh5RfbMz8DkARDXgs730QmaYtttRHXSoLXYHzu4IFururdHYVIuUrVkKKKo8Ac0VoKVCZ9vRhiCawygtrs/s320/thru-hull+scupper+sealant+%5B640x480%5D.JPG" /></a><br /><br /><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiId3OaO2wB0tw29Z03KmB1h0ZrN5dIuyWviDs4ClKx3c-kxwmgQjUuPVqN7MG5IaRNLEPWMiotV-eNFK7kz2V28GZXMntsyGCAoVBNEzvvQ7iHjkvldXUpUnK9JFnk0rcWWNLjqLfsEyVU/s1600-h/thru-hull+scupper+sealant+inside+with+nut+%5B640x480%5D.JPG"></a><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRosWMhqz3mPXDwn89kXELtW7gkwl-zHVIeOUnnMe04xhNOm4cQIaOoJE6hhHoaHV3Q_rqQE80g7xJ6gG83CIAJoJhDVighE-AR9bNGa-3LN8ZxKqEyPjgabMrrQ2J9a4KEWrgL2pxSve2/s1600-h/bottom+scupper+hole+inside+3.JPG"></a><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJFmc4f56R7O1XbBBIwHzal6f2LmtpgQKtXIzm-vVZJU7sPxVUMdOQqOCu3uB1ZSjcEw4Zq1AuAKJ-WYg5TJmqrNkJlr7UnjAYyvSttTnit0mIgMZAGZr21O9EyNoAKV1EhBoqjUrMpsCZ/s1600-h/Bottom+scupper+prep+%5B640x480%5D.JPG"></a><br /><br /><br /><br /><br />The scupper in place from the outside (still needs a little more clean up)<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFP5bqhJ1jzSP2hiefCkXOD3SQhyphenhyphen2E8kF8C3BHfmVIgfXbIbi9zkPKvknsNlioEfOHfigQo5WAiPqYTOIAVizRuKg9x52MIUvQpJC82d0ykaZCHCBczBXRKPH1DSxc1FJkZaWHgg_q6a1F/s1600-h/Thru-hull+scupper+final+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383311132137985906" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFP5bqhJ1jzSP2hiefCkXOD3SQhyphenhyphen2E8kF8C3BHfmVIgfXbIbi9zkPKvknsNlioEfOHfigQo5WAiPqYTOIAVizRuKg9x52MIUvQpJC82d0ykaZCHCBczBXRKPH1DSxc1FJkZaWHgg_q6a1F/s320/Thru-hull+scupper+final+%5B640x480%5D.JPG" /></a><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRosWMhqz3mPXDwn89kXELtW7gkwl-zHVIeOUnnMe04xhNOm4cQIaOoJE6hhHoaHV3Q_rqQE80g7xJ6gG83CIAJoJhDVighE-AR9bNGa-3LN8ZxKqEyPjgabMrrQ2J9a4KEWrgL2pxSve2/s1600-h/bottom+scupper+hole+inside+3.JPG"></a><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT7Y_NOCVk53u3Yuug8JQWEmAJ9WKIAH-FNfDSbQMx-IW85UP6N3wEJ2m3BQI8QVDw-cis3n9cvvSqukQDrQo7KbDTYW5_knkLhDc1rKSGhUfjES20U1fF5uYyJ1HeGa0vuFF2r5wDI3Om/s1600-h/bottom+scupper+hole+(2)+%5B640x480%5D.JPG"></a><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJFmc4f56R7O1XbBBIwHzal6f2LmtpgQKtXIzm-vVZJU7sPxVUMdOQqOCu3uB1ZSjcEw4Zq1AuAKJ-WYg5TJmqrNkJlr7UnjAYyvSttTnit0mIgMZAGZr21O9EyNoAKV1EhBoqjUrMpsCZ/s1600-h/Bottom+scupper+prep+%5B640x480%5D.JPG"></a><br /><br /><br /><br /><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRosWMhqz3mPXDwn89kXELtW7gkwl-zHVIeOUnnMe04xhNOm4cQIaOoJE6hhHoaHV3Q_rqQE80g7xJ6gG83CIAJoJhDVighE-AR9bNGa-3LN8ZxKqEyPjgabMrrQ2J9a4KEWrgL2pxSve2/s1600-h/bottom+scupper+hole+inside+3.JPG"></a><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhT7Y_NOCVk53u3Yuug8JQWEmAJ9WKIAH-FNfDSbQMx-IW85UP6N3wEJ2m3BQI8QVDw-cis3n9cvvSqukQDrQo7KbDTYW5_knkLhDc1rKSGhUfjES20U1fF5uYyJ1HeGa0vuFF2r5wDI3Om/s1600-h/bottom+scupper+hole+(2)+%5B640x480%5D.JPG"></a><br /><br />From the inside with extra sealant and nut in place<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiId3OaO2wB0tw29Z03KmB1h0ZrN5dIuyWviDs4ClKx3c-kxwmgQjUuPVqN7MG5IaRNLEPWMiotV-eNFK7kz2V28GZXMntsyGCAoVBNEzvvQ7iHjkvldXUpUnK9JFnk0rcWWNLjqLfsEyVU/s1600-h/thru-hull+scupper+sealant+inside+with+nut+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383309029638421058" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiId3OaO2wB0tw29Z03KmB1h0ZrN5dIuyWviDs4ClKx3c-kxwmgQjUuPVqN7MG5IaRNLEPWMiotV-eNFK7kz2V28GZXMntsyGCAoVBNEzvvQ7iHjkvldXUpUnK9JFnk0rcWWNLjqLfsEyVU/s320/thru-hull+scupper+sealant+inside+with+nut+%5B640x480%5D.JPG" /></a><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRosWMhqz3mPXDwn89kXELtW7gkwl-zHVIeOUnnMe04xhNOm4cQIaOoJE6hhHoaHV3Q_rqQE80g7xJ6gG83CIAJoJhDVighE-AR9bNGa-3LN8ZxKqEyPjgabMrrQ2J9a4KEWrgL2pxSve2/s1600-h/bottom+scupper+hole+inside+3.JPG"></a><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJFmc4f56R7O1XbBBIwHzal6f2LmtpgQKtXIzm-vVZJU7sPxVUMdOQqOCu3uB1ZSjcEw4Zq1AuAKJ-WYg5TJmqrNkJlr7UnjAYyvSttTnit0mIgMZAGZr21O9EyNoAKV1EhBoqjUrMpsCZ/s1600-h/Bottom+scupper+prep+%5B640x480%5D.JPG"></a><br /><br /><br /><br /><br /><br /><br /><br /><div></div>Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com1tag:blogger.com,1999:blog-1279193806860056180.post-71745332918087727252009-09-15T15:10:00.000-07:002009-09-19T22:30:54.146-07:00Installing the brass ball valve, "T" splitter, and reducersThe brass ball valve is the ultimate safety shut off valve. In case something goes wrong (hose burst, bag rupture, who knows???) you can shut off the entire system with the turn of one valve. This valve needs to be brass or bronze so it won’t fail like PVC could. The ball valve is 1 1/4 and screws directly onto the threads of the <span id="SPELLING_ERROR_0" class="blsp-spelling-error">thru</span>-hull scupper. I used Teflon tape to get a good seal and screwed it on good and tight. Make sure the shut off handle has clearance to open and close the valve without hitting anything. This valve should be located in an easily accessible place in case of emergency.<br /><br />The brass ball valve in place<br /><div><div><div></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcpEGWfU_bW7ZRDxyZJzIc538gBQeZIJEvNJ_x3CtjHbK8cKEi-T8BTPBQIYXuJR3zKi2DWFt-mQq97oQiG6EPc8QqvMnMsZES_UwPcciwOEUc1tMlXPIz69cl7Qe72HIlZa9QmAuWadXA/s1600-h/water+intake+with+ball+valve+close+up+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383412525959743362" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcpEGWfU_bW7ZRDxyZJzIc538gBQeZIJEvNJ_x3CtjHbK8cKEi-T8BTPBQIYXuJR3zKi2DWFt-mQq97oQiG6EPc8QqvMnMsZES_UwPcciwOEUc1tMlXPIz69cl7Qe72HIlZa9QmAuWadXA/s320/water+intake+with+ball+valve+close+up+%5B640x480%5D.JPG" /></a><br /><br /><div></div><br /><br /><div></div><br /><br /><div></div><br /><br /><div></div><br /><br /><div></div><br /><br /><div></div><br /><br /><div></div><div>Once the ball valve is in place use a 1 1/4 inch threaded to slip connector and screw the threaded end onto the brass ball valve. Use <span id="SPELLING_ERROR_1" class="blsp-spelling-error">teflon</span> tape on all your threaded fittings. Then cement (PVC cement) in a section of 1 1/4 inch PVC. I put about a 1 foot length on <span id="SPELLING_ERROR_2" class="blsp-spelling-corrected">initially</span> and then cut it down to size once I figured out how high up off the floor I wanted the "T" to be. I used the pumps height to decide the height of my "T". Cut the piece of PVC to length and cement on the 1 1/4 inch "T" making sure it is <span id="SPELLING_ERROR_3" class="blsp-spelling-corrected">aligned</span> correctly. Next cement in the 1 1/4 inch slip to threaded reducers (these reduce the "T" down to a 1" female thread). I then screw in the 1 " <span id="SPELLING_ERROR_4" class="blsp-spelling-corrected">threaded</span> hose barb connectors using Teflon tape.</div><br /><div>The ball valve, 1 1/4 inch PVC, PVC "T", thread reducers, and hose barbs in place</div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiF-uhswzOxP3y3931nTTMGASYG8rJKQXkWZ5rtSzQAgSkNsgAyyArr6bGDamxtEhEvGVoDMRlylRRtM7IPNhu8p6u2aaUxebCg9ey80YTa3kd-i_qLpG0DBNo_PyA9KdOM9O_nFMQDtY2/s1600-h/Water+intake+with+T+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383412793236353586" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiF-uhswzOxP3y3931nTTMGASYG8rJKQXkWZ5rtSzQAgSkNsgAyyArr6bGDamxtEhEvGVoDMRlylRRtM7IPNhu8p6u2aaUxebCg9ey80YTa3kd-i_qLpG0DBNo_PyA9KdOM9O_nFMQDtY2/s320/Water+intake+with+T+%5B640x480%5D.JPG" /></a></div><div></div><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyw0GvFau0tVPDPABAxwfdfdlzKCQIF2Jg1TqE4lafH7OH_P6YU9GOQH-bNwn9AJer3roLv8vzCnfG3iEAjHfg1UuzU16ZOM5CTEgw5oNj6XEYZh9wkKhJtyc7Jgpcz_IjXuWra8IdZ7D5/s1600-h/Water+intake+with+T+%5B640x480%5D.JPG"></a></div></div></div>Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com3tag:blogger.com,1999:blog-1279193806860056180.post-60932941975769792952009-09-13T15:12:00.000-07:002009-09-19T22:55:15.102-07:00The pumpsThe pumps I chose to use are Johnson Ultra Ballast pumps. They are reversible and have higher flow rates than the Jabsco Ballast Puppys. They also do not seem to have the same problems with the impellers that the Jabsco model has.<br /><br />These pumps have ½” inside threaded input/output fittings. However you can slide the 1” ID hose over the top of the input/output and hose clamp them. This will give you the best water flow without any further restriction with threaded fittings. I chose to mount the pumps to the sidewall in the V-drive compartments rather than the floor simply because the side walls have a plastic board composition and the floor has a fiberglass composition. There also was not enough clearance to get a drill into the space to drill pilot holes in the floor so I chose the wall since I could just drill screws into the side wall with out pilot holes. I used 1 ½ inch stainless steel screws size 12. I also used several ½’ washers mainly for spacing so the screws did not penetrate the other size of the wall (sharp things puncture ballast sacs!)<br /><br />I guess this is good time to mention that you should thoroughly check out the inside of the compartments that you will be putting your expensive fat sacs into! There are often times sharp pieces of fiberglass, exposed screw points, sharp wires etc. Especially check around cup holders, the rear of speakers, lights, pop up cleats, and tower mounting areas. These are notorious for sharp things and exposed screws.<br /><br />Johnson reversible Ultra Ballast pump (13.7 GPM)<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaJm5tbOVhzyiP6_cjx3msBJpeVmBbOhFFrmYvR6thqIP-tHWOow0S5UuMC597i2IrTJ8cLGlLUU1goQ0_K6m8bZPf-a9OOA7D7PcKSJZrPEJP5mGjTziVYnDdstOJtr3CCg_m3OROryns/s1600-h/johnson+pump+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383418380136206946" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiaJm5tbOVhzyiP6_cjx3msBJpeVmBbOhFFrmYvR6thqIP-tHWOow0S5UuMC597i2IrTJ8cLGlLUU1goQ0_K6m8bZPf-a9OOA7D7PcKSJZrPEJP5mGjTziVYnDdstOJtr3CCg_m3OROryns/s320/johnson+pump+%5B640x480%5D.JPG" /></a><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0YAI0Q_r4AFntbhX1-N8BLD6BFPoT5cmKqNBdHlsy90IsLkgq5Q2_5R-p9RzMlrp_s7_IBgRCEZ7id9QwtweaqyEGmnle7_ysjWIzbTlHZryaG38F7Bz5otHfNxC-OA_Vn9gdCaH_ZfQM/s1600-h/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG"></a></div>Port side pump with hoses attached (not wired yet)<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0YAI0Q_r4AFntbhX1-N8BLD6BFPoT5cmKqNBdHlsy90IsLkgq5Q2_5R-p9RzMlrp_s7_IBgRCEZ7id9QwtweaqyEGmnle7_ysjWIzbTlHZryaG38F7Bz5otHfNxC-OA_Vn9gdCaH_ZfQM/s1600-h/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383418388097173698" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0YAI0Q_r4AFntbhX1-N8BLD6BFPoT5cmKqNBdHlsy90IsLkgq5Q2_5R-p9RzMlrp_s7_IBgRCEZ7id9QwtweaqyEGmnle7_ysjWIzbTlHZryaG38F7Bz5otHfNxC-OA_Vn9gdCaH_ZfQM/s320/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG" /></a><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0YAI0Q_r4AFntbhX1-N8BLD6BFPoT5cmKqNBdHlsy90IsLkgq5Q2_5R-p9RzMlrp_s7_IBgRCEZ7id9QwtweaqyEGmnle7_ysjWIzbTlHZryaG38F7Bz5otHfNxC-OA_Vn9gdCaH_ZfQM/s1600-h/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG"></a><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_8DBgvaFWx__5Q6Xbr3BmNdcz454NeWlFuY7i7ubxlMWLkXsivLZOvteOKuTh8CV2H0RX3WKRy6q3W-JrwXDbwTbINJXVF6LrGJdWYkxmnZ7t9YOgK5wP4ppgM86zAGmZY_-B2q2P-PJm/s1600-h/starboard+pump+with+hose+and+T+installed+%5B640x480%5D.JPG"></a></div><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0YAI0Q_r4AFntbhX1-N8BLD6BFPoT5cmKqNBdHlsy90IsLkgq5Q2_5R-p9RzMlrp_s7_IBgRCEZ7id9QwtweaqyEGmnle7_ysjWIzbTlHZryaG38F7Bz5otHfNxC-OA_Vn9gdCaH_ZfQM/s1600-h/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG"></a></div><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0YAI0Q_r4AFntbhX1-N8BLD6BFPoT5cmKqNBdHlsy90IsLkgq5Q2_5R-p9RzMlrp_s7_IBgRCEZ7id9QwtweaqyEGmnle7_ysjWIzbTlHZryaG38F7Bz5otHfNxC-OA_Vn9gdCaH_ZfQM/s1600-h/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG"></a></div><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0YAI0Q_r4AFntbhX1-N8BLD6BFPoT5cmKqNBdHlsy90IsLkgq5Q2_5R-p9RzMlrp_s7_IBgRCEZ7id9QwtweaqyEGmnle7_ysjWIzbTlHZryaG38F7Bz5otHfNxC-OA_Vn9gdCaH_ZfQM/s1600-h/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG"></a></div><br /><div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_8DBgvaFWx__5Q6Xbr3BmNdcz454NeWlFuY7i7ubxlMWLkXsivLZOvteOKuTh8CV2H0RX3WKRy6q3W-JrwXDbwTbINJXVF6LrGJdWYkxmnZ7t9YOgK5wP4ppgM86zAGmZY_-B2q2P-PJm/s1600-h/starboard+pump+with+hose+and+T+installed+%5B640x480%5D.JPG"></a></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0YAI0Q_r4AFntbhX1-N8BLD6BFPoT5cmKqNBdHlsy90IsLkgq5Q2_5R-p9RzMlrp_s7_IBgRCEZ7id9QwtweaqyEGmnle7_ysjWIzbTlHZryaG38F7Bz5otHfNxC-OA_Vn9gdCaH_ZfQM/s1600-h/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG"></a></div><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0YAI0Q_r4AFntbhX1-N8BLD6BFPoT5cmKqNBdHlsy90IsLkgq5Q2_5R-p9RzMlrp_s7_IBgRCEZ7id9QwtweaqyEGmnle7_ysjWIzbTlHZryaG38F7Bz5otHfNxC-OA_Vn9gdCaH_ZfQM/s1600-h/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG"></a></div><br /><br /><div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_8DBgvaFWx__5Q6Xbr3BmNdcz454NeWlFuY7i7ubxlMWLkXsivLZOvteOKuTh8CV2H0RX3WKRy6q3W-JrwXDbwTbINJXVF6LrGJdWYkxmnZ7t9YOgK5wP4ppgM86zAGmZY_-B2q2P-PJm/s1600-h/starboard+pump+with+hose+and+T+installed+%5B640x480%5D.JPG"></a></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0YAI0Q_r4AFntbhX1-N8BLD6BFPoT5cmKqNBdHlsy90IsLkgq5Q2_5R-p9RzMlrp_s7_IBgRCEZ7id9QwtweaqyEGmnle7_ysjWIzbTlHZryaG38F7Bz5otHfNxC-OA_Vn9gdCaH_ZfQM/s1600-h/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG"></a></div><br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_8DBgvaFWx__5Q6Xbr3BmNdcz454NeWlFuY7i7ubxlMWLkXsivLZOvteOKuTh8CV2H0RX3WKRy6q3W-JrwXDbwTbINJXVF6LrGJdWYkxmnZ7t9YOgK5wP4ppgM86zAGmZY_-B2q2P-PJm/s1600-h/starboard+pump+with+hose+and+T+installed+%5B640x480%5D.JPG"></a></div><p></p><p></p><p></p><p></p><p></p><p></p><p></p><p>Starboard side pump with hoses attached (wiring not done)</p><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383418394612899058" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg_8DBgvaFWx__5Q6Xbr3BmNdcz454NeWlFuY7i7ubxlMWLkXsivLZOvteOKuTh8CV2H0RX3WKRy6q3W-JrwXDbwTbINJXVF6LrGJdWYkxmnZ7t9YOgK5wP4ppgM86zAGmZY_-B2q2P-PJm/s320/starboard+pump+with+hose+and+T+installed+%5B640x480%5D.JPG" /><br /><p></p><p><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj0YAI0Q_r4AFntbhX1-N8BLD6BFPoT5cmKqNBdHlsy90IsLkgq5Q2_5R-p9RzMlrp_s7_IBgRCEZ7id9QwtweaqyEGmnle7_ysjWIzbTlHZryaG38F7Bz5otHfNxC-OA_Vn9gdCaH_ZfQM/s1600-h/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG"></a></p>Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com0tag:blogger.com,1999:blog-1279193806860056180.post-4601652211613360012009-09-12T15:13:00.000-07:002010-11-14T18:43:37.845-08:00Hoses, hose connections, and ball valvesI initially ordered multi-flex hose from Jamestown distributing (<a href="http://www.jamestowndistributors.com/">http://www.jamestowndistributors.com/</a>) but they were <span class="blsp-spelling-corrected" id="SPELLING_ERROR_0">back ordered</span> for 2 weeks. So instead I got some 090-1 hose from <span class="blsp-spelling-error" id="SPELLING_ERROR_1">Evco</span> House of Hose. It is awesome stuff. Really strong and will not kink. It was $1.60 per foot.<br />
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Once the “T’ assembly is complete and the pumps are mounted its time to install hoses, ball valves, aux fill lines, and sac connections. I decided to start at the “T” assembly and work my way to the pump and continue on to the fat sac.<br />
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The first hose we tried to put on the “T” assembly hose barb we knew we were in trouble!!!! We soaped up the hose and the fitting and pushed like crazy for 10 minutes, strained a shoulder, and still <span class="blsp-spelling-corrected" id="SPELLING_ERROR_2">couldn't</span> get the hose all the way over the barb! We pulled the hose barb out of the boat and tried some more to no avail! So we went to Home Depot and purchased a bench vise and a heat gun. We came home and mounted the bench vise to the work bench (I’<span class="blsp-spelling-error" id="SPELLING_ERROR_3">ve</span> always wanted one anyway!). From that point forward we would place the hose barb fitting in the vise and brush on some soap. Then using the heat gun we would heat up the hose until it looked shiny and then it would slip right over the hose barb. It would shrink wrap itself around the fitting as it cooled. Way easier than the pure muscle technique that <span class="blsp-spelling-error" id="SPELLING_ERROR_4">didn</span>’t work anyway! Once again we used SS hose clamps to secure all fittings. Make sure and put the hose clamp over the hose before putting on the fitting or else you will find yourself cutting off the hose and repeating the above procedure while you swear at yourself about how stupid you are.<br />
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We ran hose from the main “T” assembly to each of the pumps. From the pumps we went only a short distance and then put another “T” in the line to go through the side walls to the auxiliary hoses. More on the aux line in a minute. Shortly after the “T” to the aux line we put a PVC ball valve in an easily accessible place. From the PVC ball valve the hose went alongside the engine and around the back corner into the port compartment there connected into the fat sacs using Flying High quick connect fittings.<br />
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Now back to the auxiliary lines. They went through the side wall (used the 1 5/8” hole saw to make the holes) into the port locker and into the starboard locker respectively. The idea was that one hose would be stored in the ski locker under the walk through and the other one would be in the large observer compartment for easy access and storage. These aux lines each have a ball valve to start/stop water flow. One has a <span class="blsp-spelling-error" id="SPELLING_ERROR_5">waterbed</span> type fitting (blue magic perfect union) and the other aux line has a Launch Pad “link” fitting to match my two older fat sacs that can be used on the seats, floor, or in the bow as needed. The hose in the starboard locker will reach anywhere in the main part of the boat. The hose in the observer compartment will reach all the way to the front of the bow.<br />
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The hoses coming off the main "T" assembly toward the port and starboard pumps<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQwoAxWzH24JM66B6EvH50b_qrxf9ekOBSTqPIUuxewKwpPy7IRP1VHhOveh0Y6F1gxuUwdIu9iYrTSdNLC8czbdCSqd-qGdMm72BasjoYWJhC8lvvVeDOG111tM9VkKPgLrneJ74OQCbA/s1600-h/Water+intake+with+T+and+hose+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383694472012321378" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQwoAxWzH24JM66B6EvH50b_qrxf9ekOBSTqPIUuxewKwpPy7IRP1VHhOveh0Y6F1gxuUwdIu9iYrTSdNLC8czbdCSqd-qGdMm72BasjoYWJhC8lvvVeDOG111tM9VkKPgLrneJ74OQCbA/s320/Water+intake+with+T+and+hose+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 240px; margin: 0px 10px 10px 0px; width: 320px;" /></a><br />
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<div>Hose from "T" <span class="blsp-spelling-error" id="SPELLING_ERROR_6">asssembly</span> to port pump</div><br />
<div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgj8zg_MxYEp_ycFTEC2XrCzRG-ASCwBOhB97p2GWoGMy-Pn6Sp63-HOwl6UB3GwsuQRW3vFpItJEV18PdC9s2uMuMz5CE5pcuCG8X1G3hJuvg0Rghigs0cTJXW7mgPkTujORz9wl0s_J3y/s1600-h/hose+from+T+to+port+pump+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383694278116115138" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgj8zg_MxYEp_ycFTEC2XrCzRG-ASCwBOhB97p2GWoGMy-Pn6Sp63-HOwl6UB3GwsuQRW3vFpItJEV18PdC9s2uMuMz5CE5pcuCG8X1G3hJuvg0Rghigs0cTJXW7mgPkTujORz9wl0s_J3y/s320/hose+from+T+to+port+pump+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 320px; margin: 0px 10px 10px 0px; width: 240px;" /></a></div><br />
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<div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgj8zg_MxYEp_ycFTEC2XrCzRG-ASCwBOhB97p2GWoGMy-Pn6Sp63-HOwl6UB3GwsuQRW3vFpItJEV18PdC9s2uMuMz5CE5pcuCG8X1G3hJuvg0Rghigs0cTJXW7mgPkTujORz9wl0s_J3y/s1600-h/hose+from+T+to+port+pump+%5B640x480%5D.JPG"></a></div><br />
<div>Hose from "T" assembly to starboard pump<br />
<div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLSxMcQtVhCqyP5Ky_YvaeW99FdwGnp148kbrTHjsEWacpaaJvyXIeiaPdyFsxiOye41hPQKR4uOqITf9P2ha1rqFBzg-pGXP-cIb6al5_HdwuMRSNQrz54NPJyGWYtOIkFkO59cNK2lMI/s1600-h/hose+to+starboard+pump+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383694180261755778" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLSxMcQtVhCqyP5Ky_YvaeW99FdwGnp148kbrTHjsEWacpaaJvyXIeiaPdyFsxiOye41hPQKR4uOqITf9P2ha1rqFBzg-pGXP-cIb6al5_HdwuMRSNQrz54NPJyGWYtOIkFkO59cNK2lMI/s320/hose+to+starboard+pump+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 320px; margin: 0px 10px 10px 0px; width: 240px;" /></a><br />
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</div><div></div><div>Hole through starboard locker wall for aux line</div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidV51LRlYiOcLQfX_h6LAh9Dsey6DV3RhOAwgwmtBFrnuGh5JALFVoK07feuMReASUvbkyLKMxM84wsuRrAX-I1tNgo-_g2YB6uLzEXInuz06R7oUUB43DUd-QiiptfmqaNjjR_FDmnawm/s1600-h/hole+through+starboard+locker+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383694000506738578" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEidV51LRlYiOcLQfX_h6LAh9Dsey6DV3RhOAwgwmtBFrnuGh5JALFVoK07feuMReASUvbkyLKMxM84wsuRrAX-I1tNgo-_g2YB6uLzEXInuz06R7oUUB43DUd-QiiptfmqaNjjR_FDmnawm/s320/hole+through+starboard+locker+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 240px; margin: 0px 10px 10px 0px; width: 320px;" /></a></div><div><br />
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</div><div>Close up of the "T" used to run the port and starboard aux lines</div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFQff8Y93MJXj66YB_61pPryrYbbxMX1LJPJt-LSPPCJWkBfK7vRV9GCwrnbnI250zjjOgvXwGscniDo9rPv06nvvjqj1mdw77naMbDSTKgfqHcRZXFUTdMvFqPx1KDqCFveoEP9YHmfJk/s1600-h/T+connector+with+hose+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383693653925971010" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjFQff8Y93MJXj66YB_61pPryrYbbxMX1LJPJt-LSPPCJWkBfK7vRV9GCwrnbnI250zjjOgvXwGscniDo9rPv06nvvjqj1mdw77naMbDSTKgfqHcRZXFUTdMvFqPx1KDqCFveoEP9YHmfJk/s320/T+connector+with+hose+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 240px; margin: 0px 10px 10px 0px; width: 320px;" /></a><br />
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Port pump with a good view of "T" going to port aux line through wall<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-R7mhd1R7s61MYh72Pskfv_KtXWApJXBKRLwUgnsEo4GqFLteiQGuj7MfxTWFYgZHcpHM-odVaTX-dI0lGr0iyEtYjSmqTnzLy6BkO9TYlt6l18_3IF30Oyq1ehxnirH6E2ICnl8GpQL1/s1600-h/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383693572981899794" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg-R7mhd1R7s61MYh72Pskfv_KtXWApJXBKRLwUgnsEo4GqFLteiQGuj7MfxTWFYgZHcpHM-odVaTX-dI0lGr0iyEtYjSmqTnzLy6BkO9TYlt6l18_3IF30Oyq1ehxnirH6E2ICnl8GpQL1/s320/port+pump+installed+with+T+to+aux+line+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 240px; margin: 0px 10px 10px 0px; width: 320px;" /></a></div><div><br />
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</div><div></div><div>Port side ball valve to control flow to/from custom sac or aux sac<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg44kWAJP4Mvx1TPu66hRt3yYjkqxJXCWXjNtuujFZPwwEfrcB2S39xDzYo3dCoU60fORKKTjghKX0YNckGa3E7ArtOQIowe9C_ENv7rE29jdgX2xQBR_zXxb9l7jDL3AwgxSO1Kmqcfdnd/s1600-h/port+side+ball+valve+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383693325209763554" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg44kWAJP4Mvx1TPu66hRt3yYjkqxJXCWXjNtuujFZPwwEfrcB2S39xDzYo3dCoU60fORKKTjghKX0YNckGa3E7ArtOQIowe9C_ENv7rE29jdgX2xQBR_zXxb9l7jDL3AwgxSO1Kmqcfdnd/s320/port+side+ball+valve+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 240px; margin: 0px 10px 10px 0px; width: 320px;" /></a><br />
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</div><div></div><div>Starboard side ball valve</div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2bGWKLG0JfHCV7T9DYeI1WZbe0z_wtyqXe59wipxpo9JI9YexM8m57Sr7LwEK_j-WqqfPkOc2FiXBvvVM87YTrF6U1GjwkqB_WqskFAV7e2V0NzFhbHjsZApTGuuvEJbB3yX4bfv_2iT-/s1600-h/ball+valve+starboard+side+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383693248503879666" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2bGWKLG0JfHCV7T9DYeI1WZbe0z_wtyqXe59wipxpo9JI9YexM8m57Sr7LwEK_j-WqqfPkOc2FiXBvvVM87YTrF6U1GjwkqB_WqskFAV7e2V0NzFhbHjsZApTGuuvEJbB3yX4bfv_2iT-/s320/ball+valve+starboard+side+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 240px; margin: 0px 10px 10px 0px; width: 320px;" /></a><br />
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Flying High quick connect. Electrical tape over hose clamp</div><div><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifgWOPinEAiJ9BY75gGUBYV89-Z6T7M7bYRQ4oL7X4O2YwLX_78jBMRiZA-wbGVoKmuZhdduNISSrxX5ziCdB8VUMQG8sj44pDfrfswEh-VXwJfdrICBs_t3BXNZ5C5-4vCiTAybWoJ4L4/s1600-h/Quick+connect+installed+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383693134911353362" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifgWOPinEAiJ9BY75gGUBYV89-Z6T7M7bYRQ4oL7X4O2YwLX_78jBMRiZA-wbGVoKmuZhdduNISSrxX5ziCdB8VUMQG8sj44pDfrfswEh-VXwJfdrICBs_t3BXNZ5C5-4vCiTAybWoJ4L4/s320/Quick+connect+installed+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 240px; margin: 0px 10px 10px 0px; width: 320px;" /></a><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxXRl1Mg68dT1VKrxKvcMXZH3CO2D0DQ8TWo0_NswB4uMKEENPCyfSg1WZ4Ry_sQOyrhVY6OiBv8KWoHnEpjvEAqJj2Px-SYFmobFzhM3VCG4H4wBqoOSjrBwLDACLrYF6YWjUEMdk-2fD/s1600-h/aux+line+starboard+side+through+wall+%5B640x480%5D.JPG"></a></div></div><div><br />
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</div><div></div><div>Aux hose coming through starboard side wall<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxXRl1Mg68dT1VKrxKvcMXZH3CO2D0DQ8TWo0_NswB4uMKEENPCyfSg1WZ4Ry_sQOyrhVY6OiBv8KWoHnEpjvEAqJj2Px-SYFmobFzhM3VCG4H4wBqoOSjrBwLDACLrYF6YWjUEMdk-2fD/s1600-h/aux+line+starboard+side+through+wall+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383692804248578978" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxXRl1Mg68dT1VKrxKvcMXZH3CO2D0DQ8TWo0_NswB4uMKEENPCyfSg1WZ4Ry_sQOyrhVY6OiBv8KWoHnEpjvEAqJj2Px-SYFmobFzhM3VCG4H4wBqoOSjrBwLDACLrYF6YWjUEMdk-2fD/s320/aux+line+starboard+side+through+wall+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 240px; margin: 0px 10px 10px 0px; width: 320px;" /></a></div><br />
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Dual quick connects on rear of custom sac<br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSmtaJeoPB6CVWBBKIc8as_bXGsSS0Y28oWt7T_K-41YKIvKKKcpvg6JjV48LRTJvvOanKkRD9KJyz6vsUEGSln9pvqbQ0bhyDn2OyCKcEJZ34E1Z3KJhjH5-xHhi4BALOu9Hnoz_1cUxJ/s1600-h/custom+sac+with+quick+connects+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383693023617436834" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSmtaJeoPB6CVWBBKIc8as_bXGsSS0Y28oWt7T_K-41YKIvKKKcpvg6JjV48LRTJvvOanKkRD9KJyz6vsUEGSln9pvqbQ0bhyDn2OyCKcEJZ34E1Z3KJhjH5-xHhi4BALOu9Hnoz_1cUxJ/s320/custom+sac+with+quick+connects+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 240px; margin: 0px 10px 10px 0px; width: 320px;" /></a></div><div><br />
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Starboard aux fill line<br />
<div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYZBL6Y5OoMmHzSu4xCGlus4MUw3w7xLdRSNionwvIf-dJpL43eun7dnVPuJTc3lYo4kEGwoddXTLe980W-H8CTb_1y8w43dpWVtQSqohaF4E_sY1sr7oZxh6v9Q9xFkAW81pCZRUuXTUr/s1600-h/Aux+line+starboard+line+%5B640x480%5D.JPG"><img alt="" border="0" id="BLOGGER_PHOTO_ID_5383692724554434434" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYZBL6Y5OoMmHzSu4xCGlus4MUw3w7xLdRSNionwvIf-dJpL43eun7dnVPuJTc3lYo4kEGwoddXTLe980W-H8CTb_1y8w43dpWVtQSqohaF4E_sY1sr7oZxh6v9Q9xFkAW81pCZRUuXTUr/s320/Aux+line+starboard+line+%5B640x480%5D.JPG" style="cursor: hand; float: left; height: 240px; margin: 0px 10px 10px 0px; width: 320px;" /></a></div></div></div><div></div><div></div><div></div><div><div><br />
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Port side aux fill line</div><div></div><div><br />
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</div></div></div></div>Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com3tag:blogger.com,1999:blog-1279193806860056180.post-33828798451889713132009-09-11T15:13:00.000-07:002010-11-14T18:45:54.534-08:00Vent/overflow line<div><span class="Apple-style-span"><span class="Apple-style-span" style="color: black;">Coming off of the top of the main part of the sac is a vent/overflow line. This line is used to vent any air out of the top of the sac so that it can fill completely with water. It is also used as a pressure overflow in case you leave you pumps running too long and risk bursting the sac.</span></span><br />
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</span></span></div><div><span class="Apple-style-span"><span class="Apple-style-span" style="color: black;">I used quick connects for this line as well. The vent line hose comes out of the sac and goes into a one way valve and then to the side through hull. The one way valve stops any water from coming in from the side through hull into the sac. It also allows the sac to raisin up and lay completely flat in the bottom of the locker when empty.</span></span><br />
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</span></span></div><div><span class="Apple-style-span"><span class="Apple-style-span" style="color: black;">I initially put on a flapper style check valve but the surging of the boat when we would start and stop would push water out of the vent/overflow. So I switched to a spring style check valve which worked better but I still would lose some water. So ultimately I put a manual check valve in line. I open it to burp the air out of the sac... other wise it is closed. I have to watch the sac to make sure I do not overfill it because there is no emergency overflow now.</span></span></div><div><span class="Apple-style-span"><span class="Apple-style-span" style="color: black;"><br />
</span></span></div><div><span class="Apple-style-span"><span class="Apple-style-span" style="color: black;">Since my install many people have started to run the vent/overflow line to the opposite side of the boat. This allows the check valve and side through hull to be much higher than the overflow on the sac (because of the leaning of the boat). Because of this lean the water does not flow out of the side through hull. With this design you can utilize a flapper or spring check valve only and it functions as it is designed. If building another ballast system I would definitely use this modification.</span></span></div></div><div><span class="Apple-style-span"><span class="Apple-style-span" style="color: black;"><br />
</span></span></div></div><div>Here is a picture of the top of the sac. You can see the quick connect in the middle of the sac for the vent/overflow line. You can also see how well the sac raisins up when it the water gets sucked out of the sac. </div><div><img alt="" border="0" id="BLOGGER_PHOTO_ID_5524423751892390738" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzhkPegFxkyMxgFDuZN2Vgsfb7U8Lvxc86lXHPWhHGvxppNgDRGIjBxehsdE4Ec3G-QvZ9EREltS51f1-Ds1-wAczBoqB8EW0FgUedSWjCa0zkkTphezjsIaG1w1CkWG86YfqLvFBArhUq/s320/Custom+sac+with+quick+connects+2+%5B640x480%5D.JPG" style="cursor: hand; cursor: pointer; float: left; height: 320px; margin: 0 10px 10px 0; width: 240px;" /></div><div><br />
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</div><div>Here is a picture of the one way check valve and then you can also see the 90 deg angle and then the side through hull.</div><div><div><img alt="" border="0" id="BLOGGER_PHOTO_ID_5524423760214753602" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiYnNMN24mcFHBdTUZ7jG8E0Fr1DkF-D0gmGJqp0IEFR5qj-y4QmpZv2AaelC8dm-i09EWegHLJAWlkN4C1omqCNXx5oC5bdD1M8jmFNiNV54WIq1vxicuu0HNqnChqtD5ANuqxw3zDwc6H/s320/vent+line+with+1+way+check+valve+2+%5B640x480%5D.JPG" style="cursor: hand; cursor: pointer; float: left; height: 240px; margin: 0 10px 10px 0; width: 320px;" /></div><div><br />
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</div></div></div></div>Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com0tag:blogger.com,1999:blog-1279193806860056180.post-790570140622538582009-09-10T15:14:00.000-07:002010-11-14T18:38:02.252-08:00Electrical<div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;">Before starting the ballast install I located 3 sets of wires tucked up under the transom lip in the back of the boat. They were heavy 10 gauge wires in 3 pairs. These were obvious factory wiring for the ballast that was never installed in my boat. I planned to use 2 of these sets for the new Johnson pumps. </div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq1PvpLrrw06wfDaEKWLhBiFWPORNQu2Q2_5VIGaF283NF7UyuMvjEeWkqT9pLgBWaog8Eg3gvzMz7dsYegCSqQbIUZYsBqT7TGounLLcbxPLgzbPg4UdvuCdyt5hOswubv4bGiUU85r2e/s1600/P5310004.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq1PvpLrrw06wfDaEKWLhBiFWPORNQu2Q2_5VIGaF283NF7UyuMvjEeWkqT9pLgBWaog8Eg3gvzMz7dsYegCSqQbIUZYsBqT7TGounLLcbxPLgzbPg4UdvuCdyt5hOswubv4bGiUU85r2e/s400/P5310004.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq1PvpLrrw06wfDaEKWLhBiFWPORNQu2Q2_5VIGaF283NF7UyuMvjEeWkqT9pLgBWaog8Eg3gvzMz7dsYegCSqQbIUZYsBqT7TGounLLcbxPLgzbPg4UdvuCdyt5hOswubv4bGiUU85r2e/s1600/P5310004.JPG" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"></a></div><div class="separator" style="clear: both; text-align: center;">This is a picture looking down the side of the boat (under the gunnel) while laying in the driver footwell area. If you notice in the wiring bundle near the top left corner you can see the same heavy gauge wires that we found in the rear of the boat. These come forward to the switch panel. <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi61hHIOh5rRG1F5ACCf4vE7wgISMbThM6ZnCAtgYDtwVvM4jq7HoboE2_vj1eepRiCXcExBQru1xfJ2qjnxFmzuozFrHYnkzAHWCR3vztpeP-jy18bFOAhjqoWKSZRna4THZ59DHcrZRj7/s1600/P5310010.JPG" imageanchor="1" style="clear: left; display: inline !important; margin-bottom: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi61hHIOh5rRG1F5ACCf4vE7wgISMbThM6ZnCAtgYDtwVvM4jq7HoboE2_vj1eepRiCXcExBQru1xfJ2qjnxFmzuozFrHYnkzAHWCR3vztpeP-jy18bFOAhjqoWKSZRna4THZ59DHcrZRj7/s400/P5310010.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi61hHIOh5rRG1F5ACCf4vE7wgISMbThM6ZnCAtgYDtwVvM4jq7HoboE2_vj1eepRiCXcExBQru1xfJ2qjnxFmzuozFrHYnkzAHWCR3vztpeP-jy18bFOAhjqoWKSZRna4THZ59DHcrZRj7/s1600/P5310010.JPG" imageanchor="1" style="clear: left; display: inline !important; margin-bottom: 1em; margin-right: 1em;"></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;"></div><div style="margin-bottom: 0px; margin-left: 0px; margin-right: 0px; margin-top: 0px;">Here is a picture of those same heavy gauge wires coming from the rear of the boat (6 heavy gauge ones plus a few others). They already had slot connectors on them and were all bundled up together.</div><br />
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</div><div class="separator" style="clear: both; text-align: center;">Here are the same 6 heavy gauge wires from the back of the boat now separated out and ready for wiring. (I only used 2 pairs and tucked the others back away for some other project)</div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;">Here is a picture of the fuse block under the driver console. On the right side you will see a separate area that has label for port, starboard, and center ballast, as well as tower lights. These all have the heavy gauge wire on them already. These wiring colors match the wires that come from the rear of the boat. There are a few fuses missing for the starboard ballast and center ballast. I followed these wires (not easy to do) and they took me to some white relays. See 2nd pic.</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEii8elvXV9Bgg1UF2FrjcoL2DURByV8TfmPdcXsStQEUsFpwnQVMVbTKw1Ju7DTC806KtvbQMJn29uPNzNGsTVOcQjKzMqUykjFu6TosRnP2OmFx6qKfZKGnT73Zf_HOKteNNG5dB-X-99F/s1600/P5310007.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEii8elvXV9Bgg1UF2FrjcoL2DURByV8TfmPdcXsStQEUsFpwnQVMVbTKw1Ju7DTC806KtvbQMJn29uPNzNGsTVOcQjKzMqUykjFu6TosRnP2OmFx6qKfZKGnT73Zf_HOKteNNG5dB-X-99F/s400/P5310007.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;">These are the white relays that the wires from the fuse block go into. I was able to follow them through the other side of the relay and then to an area behind the switch panel where they were bundled together with slot connectors on them. </div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKNPRSfFCupbgrdBZGTeTbQYWvu1II3atu1QIt8X9GtGxzHhvwG2b38uirK2YiYfpYjO2YsNUqVG8V_HeI8DDOLW8d1ELl0zrd75VzSVbrJUxs_0ONiHKF0-QvgLvFQukoWphi5jurNVwk/s1600/P5310012.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKNPRSfFCupbgrdBZGTeTbQYWvu1II3atu1QIt8X9GtGxzHhvwG2b38uirK2YiYfpYjO2YsNUqVG8V_HeI8DDOLW8d1ELl0zrd75VzSVbrJUxs_0ONiHKF0-QvgLvFQukoWphi5jurNVwk/s400/P5310012.JPG" width="300" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;">So all the wiring was in place except for there were no ground wires coming from the fuse block. Only hot wires. So I obtained some 10 gauge wires and ran two wires from the grounding slots on the far left of the fuse block (see fuse block picture above) to the rear of the switch panel. I used green wire because its all I had. The fuse block picture does not show the green ground wires yet. The following picture shows the switches that came with the Johnson pumps. I did not like how they looked because they did not match the factory switches. But I tried to use them anyway. I got them all wired up and they worked great..... However they did not fit into the slots of the switch panel board. </div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigoGGVQYAr2Z63EWAAnhXKP02YY55PAOyhXXuQDM5Mj_4MIwucvq-0gUqdfeHDoTxErF3SLX_KeZP094b2gqzs9uD3I8j7xgtM0ZfZRWMNDg_dtX4Z9jgDPMMeP8avXJD811gAIRDiHpQi/s1600/switch+panel+2.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEigoGGVQYAr2Z63EWAAnhXKP02YY55PAOyhXXuQDM5Mj_4MIwucvq-0gUqdfeHDoTxErF3SLX_KeZP094b2gqzs9uD3I8j7xgtM0ZfZRWMNDg_dtX4Z9jgDPMMeP8avXJD811gAIRDiHpQi/s400/switch+panel+2.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;">So I ordered factory switches from Fineline. Shell was a big help there. These are what the starboard and port factory switches look like that match my other switches.</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu1ocI1wZO-Wu3CarVC03_PvgdFx3iu6OM34an0N8tNmC5IiWzXlg9lMfOtCnPhiyhBNGAZhh1e2udFTxIyTlFwsuHcOodW6Okxv67-wYe2HhA8L9Siosb12ZcswXka_BZJcjC5LDq58iU/s1600/P6150021.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhu1ocI1wZO-Wu3CarVC03_PvgdFx3iu6OM34an0N8tNmC5IiWzXlg9lMfOtCnPhiyhBNGAZhh1e2udFTxIyTlFwsuHcOodW6Okxv67-wYe2HhA8L9Siosb12ZcswXka_BZJcjC5LDq58iU/s400/P6150021.JPG" width="300" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRpU624SpJJqKj1VszuTnLG96d_yRBy0A5QQpC243-6aCsFx0VQjsfVX0m9goBA1ZsKbB7bOEJXLqcIDD-PeOvJK2rpswBh0p8injAXFO8CeI4EiH53U2ONzEooWNojB661RYNxhB2i1lZ/s1600/P7050005.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRpU624SpJJqKj1VszuTnLG96d_yRBy0A5QQpC243-6aCsFx0VQjsfVX0m9goBA1ZsKbB7bOEJXLqcIDD-PeOvJK2rpswBh0p8injAXFO8CeI4EiH53U2ONzEooWNojB661RYNxhB2i1lZ/s400/P7050005.JPG" width="400" /></a><br />
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</div><div class="separator" style="clear: both; text-align: center;">Unfortunately the switches from Fineline have the incorrect wiring pins in the back of them for use with a reversible pump like the Jabsco or Johnson pumps. These switches are designed to be used through a relay of some sort and use a ballast puppy to fill and mayfair pumps to empty. Here is what the pins on the back of the factory switches look like. There are only 5 pin connectors.</div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUZ32hGUEfJhToYWvE9O-rEo1uZ7_HD9QALf2nfU1xyHt9KhMRY_4PcwWPEC6IX5npWdQJDDhULLpnEUAg3Brj7ToHdy7vYtUUGomnI2qql8LcSyzMyw1QjlmwviI7ykByreChudjoNQkS/s1600/P6150023.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiUZ32hGUEfJhToYWvE9O-rEo1uZ7_HD9QALf2nfU1xyHt9KhMRY_4PcwWPEC6IX5npWdQJDDhULLpnEUAg3Brj7ToHdy7vYtUUGomnI2qql8LcSyzMyw1QjlmwviI7ykByreChudjoNQkS/s400/P6150023.JPG" width="300" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;">So I decided to order some different switches. I found these switches on Ebay at a store called The Boating Mall... <a href="http://stores.ebay.com/theboatingmall">http://stores.ebay.com/theboatingmall</a> . I took a picture of the switch packaging so you have the correct switch number and everything. These are double pole double throw (DPDT) switch that also has the LED light on them. They are generic switches with generic face plates with no writing on them. They do fit in the holes in the centurion switch panel. So what I did is pop the face plates off of the switches I purchased from Centurion and swapped them with the face plates on the switches from Ebay. So now i had the correct switch body and now also had the matching factory face plate with the correct ballast text on them. Here is the switch packaging. It is a Cortura rocker switch number 12982. Make sure and get the illuminated one if you want the LED lights to work. </div><div class="separator" style="clear: both; text-align: center;"><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgamLgfOHUQy_sP8l1kOvn46bpnHGXdxNO4gOmD1VKJddDWIUHftmcHtUA79dkB4u1tlIFB0s4Fl682Ny8K4vplDvD8hc-TRMXl8F5uSCYDfPYlk_XoRDVgaLexUINjtNU-Fdb4ScQNichyphenhyphen/s1600/P7050010.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgamLgfOHUQy_sP8l1kOvn46bpnHGXdxNO4gOmD1VKJddDWIUHftmcHtUA79dkB4u1tlIFB0s4Fl682Ny8K4vplDvD8hc-TRMXl8F5uSCYDfPYlk_XoRDVgaLexUINjtNU-Fdb4ScQNichyphenhyphen/s400/P7050010.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;">Here is what the back of the new switches look like. There are 7 pins. </div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBrcjS2jyNB4cLws69Wwx0g4UbG_vPxs6rETnOqgWKYTJDL9xGUGQd2gtYrwvxwBhH3Mgau7RHLq3gjV88ZpKgX5PhSScfPSfR9Iso_VeY9TMeuH1dNSKSuf8HD_RwDsmV1gxKBzNYGTE-/s1600/P7050006.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgBrcjS2jyNB4cLws69Wwx0g4UbG_vPxs6rETnOqgWKYTJDL9xGUGQd2gtYrwvxwBhH3Mgau7RHLq3gjV88ZpKgX5PhSScfPSfR9Iso_VeY9TMeuH1dNSKSuf8HD_RwDsmV1gxKBzNYGTE-/s400/P7050006.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;">Now for the switch wiring. There are 7 pins on the rear of the switch. There are 3 in the left column and 4 in the right. They are numbered as follows: The top left is 1, the middle left is 2, the bottom left is 3. The top right is 7, the 2nd on right is 4, the 3rd on the right column is 5, and the bottom right is 6. So here is how I wired mine. Hot wire from the fuse block goes to 5. Ground wire from the fuse block goes to 2. Run a loop from 2 to 7 to get the LED light to work. Run the wires that are going to/from your pump to 3 and 6. Run a loop from 3 to 4 and from 6 to 1 (this steps allows the pump to reverse). Hopefully that works. This next part is kinda complicated. Now you have to test the switch and pump. At this point I disconnected my ballast sacs and filled a 5 gallon bucked with water. I put the hose to the ballast sac into the bucket. I then hit the fill switch. If hooked up correctly the hose will blow bubbles into the water (sucking air from the intake and pushing it into the water. If that happens then great. Then hit empty. If hooked up correctly then water should start sucking from the bucket and coming out the bottom thru hull. If this happen great!!! If just the opposite happens (sucking water with fill and blowing bubbles when empty) then you need to reverse wires 3 and 6 and their corresponding loops to 1 and 4. That will fix that problem. The other potential problem is if the empty LED light comes on when you hit fill and visa versa. If this happens pull the switch out of the panel. Pop off the face plate and turn it over and pop back on. Then put switch back in the panel. So essentially you just turned the switch upside down. That will fix the LED light problem. Here is a picture of the wiring of the back of the switch. Make sure and buy big enough wire diameter connectors so that on several of them you can push 2 wires in them before pinching them down (pins 2, 3, and 6). In this picture the green wire is ground from fuse block to #2, Reds are loops from 3 to 4 and 1 to 6, Thin black wire is loop from 2 to 7, Large black wire with blue stripe is wire from pump as is the large darker brown wire (hot and ground does not matter here. You just want the pump to spin the correct way for fill and empty), the light brown wire with a blue stripe is hot from fuse block. </div><br />
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</div><div class="separator" style="clear: both; text-align: center;">Here is the butt connectors I used to connect the factory wires near the rear of the boat to the pump wires. I used liquid electrical tape (red stuff) to make the connections waterproof. The wire was then put inside the plastic black spiral conduit and taped shut with electrical tape. </div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUt0hl3CPHY4qK8r64hVFLkk2bhQmQQAJaTy1Bv9BTK-2Pp0eZTtCvkDuyibnvuMjpvsCGQwf3ycmZItfgkeohdQE3pG0R8_NySzlBRVspym2wrYmcwr1ZjYmWUQ05DWt7QFsb02CC1eXq/s1600/water+proof+butt+splice+2.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUt0hl3CPHY4qK8r64hVFLkk2bhQmQQAJaTy1Bv9BTK-2Pp0eZTtCvkDuyibnvuMjpvsCGQwf3ycmZItfgkeohdQE3pG0R8_NySzlBRVspym2wrYmcwr1ZjYmWUQ05DWt7QFsb02CC1eXq/s400/water+proof+butt+splice+2.JPG" width="400" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: center;">Here is the finished switches in place. Looks clean and just like a factory install!</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxLHkmTufJIIgI6NiJcmakcmt4vM1BvHrOuLijHW5v9CUyioIELKfsEFh18LQcsWGEsHVHx-e8xkipE-XGqaTVaS06f_D8tDm854JTn4dHxC-HqyQWc7g4mdnsq_OVFNyXe3KhdQwJdtmW/s1600/P7050009.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="300" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxLHkmTufJIIgI6NiJcmakcmt4vM1BvHrOuLijHW5v9CUyioIELKfsEFh18LQcsWGEsHVHx-e8xkipE-XGqaTVaS06f_D8tDm854JTn4dHxC-HqyQWc7g4mdnsq_OVFNyXe3KhdQwJdtmW/s400/P7050009.JPG" width="400" /></a></div>Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com0tag:blogger.com,1999:blog-1279193806860056180.post-34920266220294299992009-09-09T15:14:00.000-07:002009-09-20T20:30:56.951-07:00Fake a Lake testSo I figured the first thing I needed to do once the system was completely put together was to see if the system itself worked. Would the pumps actually pump the water in and out. Also a great time to check for leaks in hoses, clamps, etc. <br /><br />So I hooked the fake-a-lake up to the water intake for the ballast system, not the water intake for the motor. I turned on the hose and then jumped in the boat. I wanted to try out each pump individually so I started with the starboard pump and switched the switch on to fill. The moment of truth..... The pump fired up and water started flowing through the hoses and into the custom sac. I could also get water flow through the starboard aux fill line. And no leaks! I then tested the port side the same way. Success! <br /><br />I took off the fake-a-lake and then reversed the process and hit empty on the port side and sure enough the pump reversed and shot water back out the floor intake. Same thing for the starboard side. <br /><br />I did not fill up the ballast sac very much just cause I didn't want all the additonal weight in the boat. Its not good for the boat or the trailer. <br /><br />Now it was time to go launch the boat and check for leaks in the new "holes in the boat".Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com0tag:blogger.com,1999:blog-1279193806860056180.post-17644024247519482592009-09-08T15:14:00.000-07:002009-09-21T13:49:39.593-07:00Water test...... hope this works!!!!Ok the moment of truth has arrived. Time to see if the boat still floats. I went down to the lake and launched the boat. To start off I had the brass ball valve closed. I wanted to make sure the water intake scupper was water tight. I watched it for about 5 minutes and no leaks.<br /><br />Next I opened up the ball valve to which allowed water into the system to as far as the pumps. The pumps are a closed type system and will not allow water past the impeller. I watch for about 5 minutes and no drips or leaks.<br /><br />At this point I was getting impatient so I hit the fill switches for both pumps and we headed out into the lake anxious to get some surfing action. After about a 5 minute ride I stopped and opened the V-drive locker under the rear seat. HOLY CRAP!!!! THE BILGE WAS FULL OF WATER! My bilge pump had kicked out but I didn't notice. I immediately shut off the ballast pumps and regathered myself. The bilge pump cleared out all the water and no more seemed to be coming in. So I turned on just the port side pump this time and we watched and listened. Pretty soon the bilge started filling up again but the water was coming from the front of the boat. What the Heck???? Then is dawned on me. I had forgot to shut the ball valves on the aux fill hoses. So I opened up the starboard locker (ski locker under walk thru) and sure enough... soaking wet. And I opened up the observer compartment...... sure enough soaking wet! Ok major oversite. I won't do that again!<br /><br />So after shutting off the aux hose ball valves I hit fill on both pumps. Everything worked like a charm. The bag filled the compartments completely! They emptied perfectly as well. Success!Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com1tag:blogger.com,1999:blog-1279193806860056180.post-47220346461238985532009-09-07T15:15:00.000-07:002009-09-20T21:16:01.508-07:00Results... Fill & empty times, pics of waveThe the custom install worked awesome! I timed the fill and empty times and it takes exactly 7 minutes to fill the custom Avy sac with both pumps running. If I am also filling any aux sacs then the time increases. My usual set up is to fill the custom sac completely, fill a 500# sac on the back seat completely, and also a 200# sac in the bow completely. To fill all of these sacs simultaneously it takes about 11 minutes. About the same amount of time to drain them but maybe a little faster. The system will both fill and empty while sitting still in the water or while the boat is moving. I was a little concerned about how well it would drain while under way because of water being forced into the water intake. It seems to slow the draining down a little but not significantly. <br /><br />The only slight problem I have with the system that I was not anticipating was that the aux fill lines do not have very much pressure when filling. The pumps are so powerful they shoot the water right past the "T" that goes to the aux fill lines. The aux lines get some flow but not very much. I got around this by slightly closing the inline ball valves that go to the custom sac. That way there is not quite as much pressure going to the custom sac and it forces some into the aux fill lines. I just keep them slightly closed (mostly open) all the time now. This allows me to fill/empty the custom sac as well at the 2 aux sacs that I always use at will. Fill/empty time with the valves like this is 11 minutes.<br /><br />Now I can launch the boat, hit the fill switches, pick up my tow vehicle park guy, and by the time we go wakeless out of the marina the ballast system is full and we are ready to ride. No more wasted 20 minutes once we get out of the marina to fill the ballast. Although the ballast install was rather expensive it gives us 30-40 minutes extra riding time every time out. And to not have the headache of several manual pumps and moving stuff everywhere is worth it alone.<br /><br />Here are a couple more pics of us surfing. I am 6'3" and well lets just say 250+ to be nice. The wave is large, long, and tons of push even for us big guys.<br /><br />Also included 2 pics of how the custom sac looks filled up in the compartments. This was filled with air before the install was complete. I keep meaning to get some pictures of it full of water on the lake but keep forgetting. Too much surfing fun to be had! <br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5XdwLjavrdNTCMu3rtked1KXmgj2epQoGZv0AU3Zfr8uC3kZczB7-Oxmvo5WesR77iFsbKO0pioCiIjUAQE4Q-2btnjuoxKqY6DXXgAsSQ-xiHpjlqhlnUiFkkVjN-itbrPzcjYybPJMd/s1600-h/P6230115.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383765915671885362" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5XdwLjavrdNTCMu3rtked1KXmgj2epQoGZv0AU3Zfr8uC3kZczB7-Oxmvo5WesR77iFsbKO0pioCiIjUAQE4Q-2btnjuoxKqY6DXXgAsSQ-xiHpjlqhlnUiFkkVjN-itbrPzcjYybPJMd/s320/P6230115.JPG" /></a><br /><br /><div></div><br /><br /><div></div><br /><br /><div></div><br /><br /><div></div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXenREjtQgFAFuMlvok9QqEngsghgAxDPmB-6oQfLv0bCPWelUUZPDVXxoPsGrZKnIkFaVTYAvSy5GZihw5DUnMIi94de71a11Pt9BcoDkC7vbYBumqpuNVJkXKyHkTj2rqeOySa_LlxHP/s1600-h/P7250244.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383765926303717042" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXenREjtQgFAFuMlvok9QqEngsghgAxDPmB-6oQfLv0bCPWelUUZPDVXxoPsGrZKnIkFaVTYAvSy5GZihw5DUnMIi94de71a11Pt9BcoDkC7vbYBumqpuNVJkXKyHkTj2rqeOySa_LlxHP/s320/P7250244.JPG" /></a><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjauPGXoZqfRQ5ekmQYlNpXRCLucSKwqspUQW7GjLzpSuZapR4gBWPxie_dVbr8Xqfbn64Pqt4mD6JxplfUm6zRx4hF7ehcnFz8FbB5CXIguJuSA5bd13qQKVNbki13euvKU8hyVKMs2DRu/s1600-h/P6020017.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383763332923453058" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjauPGXoZqfRQ5ekmQYlNpXRCLucSKwqspUQW7GjLzpSuZapR4gBWPxie_dVbr8Xqfbn64Pqt4mD6JxplfUm6zRx4hF7ehcnFz8FbB5CXIguJuSA5bd13qQKVNbki13euvKU8hyVKMs2DRu/s320/P6020017.JPG" /></a><br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjn4nosKdBp508FFDgIbnz2fLSwwGJZY6rdRN6AEr1K6d7e2XFgSCC4b-u2OvDJ_d8fiZaHq2wKrktQi521VkqEX0iKaoCaqbK40Cc8kUMKGNzkQo1WpspzEtKTJ-v5GvaNtPdJO4Z0VzcU/s1600-h/DSCN5245.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 240px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383763327991146210" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjn4nosKdBp508FFDgIbnz2fLSwwGJZY6rdRN6AEr1K6d7e2XFgSCC4b-u2OvDJ_d8fiZaHq2wKrktQi521VkqEX0iKaoCaqbK40Cc8kUMKGNzkQo1WpspzEtKTJ-v5GvaNtPdJO4Z0VzcU/s320/DSCN5245.JPG" /></a><br /><br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9clYZcPbadjS1bWYUPulMjYDgzn7CuVBKqS5Hdk-IRPvejkCvcvzO1xXXR4TmWIsJF5ZqA-iR-Z28uiOQMUycf7O2cjU8OpGMVU6FVPSA4pmK5mR_zBsHiEW3D0sAW_d_c6EciQJSGgaX/s1600-h/6168_133757897928_843022928_2317276_8165835_n.jpg"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 320px; FLOAT: left; HEIGHT: 213px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383763317205666562" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg9clYZcPbadjS1bWYUPulMjYDgzn7CuVBKqS5Hdk-IRPvejkCvcvzO1xXXR4TmWIsJF5ZqA-iR-Z28uiOQMUycf7O2cjU8OpGMVU6FVPSA4pmK5mR_zBsHiEW3D0sAW_d_c6EciQJSGgaX/s320/6168_133757897928_843022928_2317276_8165835_n.jpg" /></a><br /><br /><br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAM4oZvdVBRLzjwX04AXz6wkXxmbgBI0lSa74MsVyAKutqipfhQlZqRS-YqH4GaTHYWpKvWL4NLTTu2W1KU0K5PVr_FJ7lKo7ojCIKZyUpxF3HZPcv0F3LZsA5rVaZQKSP-ZvhBpgdGivp/s1600-h/custom+sac+in+port+sac+2+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 240px; FLOAT: left; HEIGHT: 320px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383763314368903490" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAM4oZvdVBRLzjwX04AXz6wkXxmbgBI0lSa74MsVyAKutqipfhQlZqRS-YqH4GaTHYWpKvWL4NLTTu2W1KU0K5PVr_FJ7lKo7ojCIKZyUpxF3HZPcv0F3LZsA5rVaZQKSP-ZvhBpgdGivp/s320/custom+sac+in+port+sac+2+%5B640x480%5D.JPG" /></a><br /><br /><br /><br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPOySltnKdLrXXahI4DklLGhzpf6pr9jZaCuZ6DqD48hzgaXnfuAQsiQw07ko_foNl_buTAn_eIlTOluuTIn4LuIQ_liS4yInk1wNyDgcseKAP6NQFl9beWE2yprI-25r_3qkgRXNi4QLh/s1600-h/custom+sac+in+place+%5B640x480%5D.JPG"><img style="MARGIN: 0px 10px 10px 0px; WIDTH: 240px; FLOAT: left; HEIGHT: 320px; CURSOR: hand" id="BLOGGER_PHOTO_ID_5383763305007760082" border="0" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhPOySltnKdLrXXahI4DklLGhzpf6pr9jZaCuZ6DqD48hzgaXnfuAQsiQw07ko_foNl_buTAn_eIlTOluuTIn4LuIQ_liS4yInk1wNyDgcseKAP6NQFl9beWE2yprI-25r_3qkgRXNi4QLh/s320/custom+sac+in+place+%5B640x480%5D.JPG" /></a><br /><br /><br /><br /><br /><br /><br /><div></div></div></div></div></div></div>Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com2tag:blogger.com,1999:blog-1279193806860056180.post-21464281632052755352009-09-06T15:16:00.000-07:002010-11-14T18:59:06.958-08:00Hindsight is 20/20... What I would have done differentActually there is very little I would have done different. I have made 2 small modifications from the original design. <br />
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The first is I lengthened the aux fill hose in the port observer compartment. I needed it to reach all the way to the front of the bow for filling the bow sac. I may actually hard plumb in this sac under the port bow seat and add a overflow/vent line to it to make things even more simple.<br />
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The second one I have already talked about in the vent line install section. I had to install a ball valve in the vent line to keep from loosing water out of the custom sac as the boat would start and stop. I originally thought the spring loaded one way valve would keep enough pressure to keep the water from free flowing out. And for the most part it keeps it from free flowing but the surging of the water during boat starting and stopping pushes water out and you loose a fair amount of water out of the top of the sac after an hour or so. <br />
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Installing the ball valve fixed that problem. I actually leave the ball valve closed most of the time now. I am careful to watch the sacs as they are filling so I don't overfill them because I have the overflow shut off essentially. I only really open the ball valve when I need to burp some air out of the top of the sac. However on my next ballast system I will run the vent/overflow line to the opposite side of the boat. This will completely eliminate the water getting pushed out of the sac with the boat surging and it will allow the overflow and vent to work without having to use a manual ball valve. <br />
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The only other problem was the initial low pressure in the aux fill lines that I mentioned in the results section. I discussed in there how I worked around this problem and I am very happy with the solution and results.<br />
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One other modification I have make lately is that I replaced my older Fly High sac that had the older water bed style connectors with a new Fly High Pro X series sac that has the good quick connects. I also replace the old Launch Pad sac with a new Fly High Pro X sac. So I took the end connectors off of the aux fill lines (one was water bed style and the other one was for the launch pad link system) and replaced them with Flying High part W738 (<span class="Apple-style-span" style="color: #363636; font-family: Verdana, Geneva, Kalimati, sans-serif; font-size: 12px; line-height: 17px;">MALE QUICK CONNECT - 1 1/8" BARBED TSUNAMI PUMP HOSE END) .... </span><a href="http://shop.maxwake.com/product.sc?productId=48&categoryId=12">http://shop.maxwake.com/product.sc?productId=48&categoryId=12</a> I had to really heat up the end of the 1" hose to fit over the 1 1/8 inch barb filling but it worked good. Now I can fill my two new FH Pro X 400# sacs from the aux fill lines. These FH Pro X sacs are so much nicer then the other brands of sacs. More durable and much better connectors!Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com0tag:blogger.com,1999:blog-1279193806860056180.post-45911220815670754502009-09-05T15:16:00.000-07:002010-11-14T18:48:42.474-08:00Modifications for other ballast systemsMy ballast system is a two pump system to fill one very large main sac for surfing . It also has the auxiliary hoses to fill sacs on the seat, floor or bow. This system can easily be adapted to fill 2 large sacs that are in both rear lockers. Also by building a manifold that has 3 or 4 main lines off of it (I used 1 “T” on the main water inlet/outlet so I only have 2 main lines.) you could also fill a center or bow ballast sacs. This general idea can be adapted to many different set ups.Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com0tag:blogger.com,1999:blog-1279193806860056180.post-57862390609110239772009-09-04T15:17:00.000-07:002009-09-19T15:20:26.773-07:00Contact information and suggestions for future ballast buildersI can be contacted by email at <a href="mailto:bigcatpt@gmail.com. ">bigcatpt@gmail.com. </a><br /><br />I would be happy to answer any questions you have. I also have a lot more pictures that may be helpful for your install. <br /><br />I also welcome any recommendations you have for changes that would be helpful for this ballast install document. As you build your system feel free to send me some pics or modifications that you did that may be helpful to whoever looks at this document. <br /><br />Thanks! Steve (Aka Bigcatpt)Steve Robbinshttp://www.blogger.com/profile/10008913044341778632noreply@blogger.com0