New jet pump housing

My new jetski pump just arrived. The old housing was really corroded and out of round, this new one is muuch better nick, as you can see if you look at them side by side:

Hmm, the budget really is getting eaten into though:
Cost: $120
Total so far: $320
Hopeful end budget: $1000
Money remaining: $680

Investigating this, investigating that. General investigation.

After several discussions via email and on forums, i'm second-guessing my decision to use a jetski pump and motorbike engine. A few options now present themselves:
* Use a smaller bike engine (eg a 110cc engine) for less weight and better physical fit
* Build a bigger boat (a glen-l squirt seems to be a common option)
* Just put a 10hp outboard on the back
and, of course my favourite option:
* Continue on my current mad path

I've researched to find that 2-stroke short shaft 10hp motors all seem to weigh around 36kg. Now when the hull was designed decades ago, i'm sure that those motors used to weigh more, lets say 45kg.
I just weighed my jet pump on the bathroom scales and found it to weigh 20kg. Now i believe i can shave 5kg at least off that when chopping it down to fit better. So, that leaves 45-15=30kg for my bike engine. I haven't weighed it yet, but if it's around 30kg, i can put it in the boat knowing that all up, i'm weighing the same as an outboard. So i just need to weigh the bike engine now. Its tricky hanging on to these heavy things while balancing on the bathroom scales!

Also have found a nearby (ish) timber store that knows about boatbuilding timbers.

Plans arrived!!!

So excited to see a nice fat envelope when i got home from work today:

The plans arrived!!!

Its alive!

Finally got the bike / boat engine to start! Awesome!
There's nothing that start-ya-bstard stuff won't get going :)

Plus a bit of angle grinding to get the airbox and the carby out of the way. I'm sure there's a way to get them out without chopping the frame in half but this was easier and more fun :)

Jet pump + Karcher

Finally got my karcher back off a mate! So today i took out the jet pump and got started cleaning it, by blasting the majority of the corrosion off it.
A before shot:

And after:


It looks like part of the jet pump needs welding to strengthen it a bit. I don't know what type of metal it is! Gal, Staino, or Alu, not sure. I'll give it to my bro-in-law to figure out.

Also the prop scrapes on the wear ring a bit. Quick fix: i'll grind it down just a little. This doesn't need to be perfect.

More carby fun

Found out what those bits on the carby are. The top left one is for the choke/starter valve. I can block that off (and the holes that feed it) with some epoxy.
The other one is to provide atmosphere pressure to the carb bowl. So i can leave it disconnected.
Other than that, found out that the carb is a Keihin CVK40, and is likely shared with these bikes:

BR250 (my donor bike)
KLR250
KL250
KSF250
EL250
EX250

So finding parts shouldn't be too hard. I need lots of orings and replacement parts that are broken in it, unfortunately. Might be simpler to get another carb.

Carby fun

Just finished reassembling the carby after cleaning it all out and leaving it to soak in kerosene for a night. Had to use a compressed air blower to clean out the fuel intake! Gummed up good that bit was... the rest looked OK. Oh and the soak freed up the throttle which was good, it was nice and stuck before. Did you know that kero is the main ingredient in WD40 (AFAIK) ?
Anyway the carb looks okayish, the status report:
The pin that connects to the float to stop fuel coming in when it's full is broken a bit, may need replacing. There looks to be something that screws in missing from the top left of the photo, and there is another what looks to be a fuel line connector (just right of the missing bit, aiming rightwards), but i'm not sure what it's there for.