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  1. #1
    Moderator OsideBill's Avatar
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    Pump tunnel reinforcement Install (Pre-Fab)

    Here it is as promised.

    I know everybody has an opinion on these this is how I do it.

    First and foremost. Seal your pump shoe first!!!!! There are several threads on this. Now once this is done and cured we can begin the tunnel reinforcement install.
    1. Remove Battery
    2. If you have OEM Sound Suppresion Remove it.
    3. Remove all hoses that go to the transom.
    4. Remove the strap and bracket for the water box.
    5. Remove pump shoe bolts.
    6. Remove The green glue and pump shoe inserts.
    7. Sand the hex shape that located the inserts flush to the hull.
    8. Sand the rib next to the waterbox strap bracket.
    9. Test fit the Tunnel reinforcement it should pop right on with a little finesse
    10. Drill holes through reinforcement using the Pump shoe holes as your guide. note: use 3/8" drill bit, also a second person to hold the reinforcement from moving helps, or do as I do and improvise
    11. Fit the inserts to the reinforcement.
    12. Test fit everything prior to gluing
    13. Glue everything in place
    14. Install Pump shoe bolts and torque to spec. (12ft/lbs.)
    15. Clean up any misplaced glue with acetone.
    16. Re-install hoses, WB bracket, battery tray etc.
    Parts needed:
    • 305Coco Pump Tunnel Reinforcement (available in the Green Hulk store)Click
    • (2) Pump shoe brackets Yamaha P/N F1G-U8571-00-00 also available through the Green Hulk store less than $20 for both
    Supplies needed:
    • Your choice of glue (mine was 3m 5200 fast cure)
    • Acetone
    • Masking tape
    • Rags
    • Sandpaper 60-80 grit
    • Latex gloves
    Tools needed:
    • Heat Gun
    • Hammer
    • Small 90* or straight sander or die grinder
    • Basic hand tools for removing battery box, hoses, etc.
    • Pry bars or air chisel
    • Torque wrench
    • Drill motor with 3/8" bit
    Installation time approx 2 hours (more if you have to continually stop and wash up to take pictures for a "how to" thread
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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    Last edited by OsideBill; 05-12-2011 at 10:37 PM. Reason: Added link


  2. #2
    Moderator OsideBill's Avatar
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    • I use a heat gun and get the green goo hot until it starts to change color, it takes time a good 3-5 minutes of heat. Then I put a screw in the insert and smack it with a hammer. had about 50-50 luck getting everything using this method. I use my air chisel to remove anything that remains.
    • I Then use a small 90* air sander with a 1-1/2" sanding disk to smooth the hull out. it is also necessary to smooth down the rib next to the waterbox hold down bracket.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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    Last edited by OsideBill; 02-21-2008 at 01:32 AM.

  3. #3
    Moderator OsideBill's Avatar
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    • I then test fit the Reinforcement to make sure everything sits flush on the bottom of the hull, and that there is noting holding it up off the tunnel.
    • Now I drill the holes. I use a 3/8" drill bit for this. It is best to have a second person for this task. They will hold the reinforcement down in place while you drill the holes from under the ski. Use the pump shoe bolt holes as a guide. (I did not have a second person, so I improvised and used a large punch to wedge the piece in place)
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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    Last edited by OsideBill; 02-21-2008 at 01:32 AM.

  4. #4
    Moderator OsideBill's Avatar
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    • Now you have to trim and fit the Pump shoe brackets. These can be cut and sanded to fit. I milled mine.
    • I also sanded a slight bit on top of the reinforcement to get a perfect fit.
    • Now install everything and fit test to make sure everything lines up properly. Put the bolts in and snug them for this test. look at all the edges to make sure everything looks right.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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    Last edited by OsideBill; 02-21-2008 at 01:32 AM.

  5. #5
    Moderator OsideBill's Avatar
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    • Scuff all surfaces to be glued with sand paper both tunnel and reinforcement
    • Clean all surfaces to be glued with acetone.
    • Use painters tape to tape off any areas, fittings and cables thet you do not want glue on.
    • Apply glue to the pump shoe and spread evenly
    • Apply glue to pump tunnel in areas where reinforcement will mate.
    • Install reinforcement
    • Apply sealant (3m 5200) to the brackets and install in reinforcement.
    • Install Pump shoe bolts and torque to spec. (Helps to have some one hold the brackets in place while you install the bolts) . Re-torque bolts again in 30 minutes.
    • Use Acetone to clean up any unwanted glue.
    • Re-install all hoses and battery box your done.
    Note: Due to the excellent fit of this piece, it does not require a huge amount of glue. I used about a third of the tube of 5200 and this included doing the inserts. I spread it out evenly on both the tunnel and the shoe. I used more around the area where the bolts go through the hull. When you test fit the piece try and judge what it will take to get the two pieces mated and get minimal squeeze out. The glue you see around the edges in my install is actual squeeze out. I did not remove or add anything post of install, other than the glue under the pump shoe brackets.
    Attached Thumbnails Attached Thumbnails Click image for larger version. 

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    Last edited by OsideBill; 03-10-2008 at 09:14 AM.

  6. #6
    Moderator OsideBill's Avatar
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    This part fit like a glove. I had very little trimming to do compared to the R&D piece. 305coco (Jorge) deserves a huge round of applause
    And a big Thank you from us for taking on the task of making these. Thanks Jorge!!!!!

  7. #7
    Caution raider fan in the area !!
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    Bill, Great Pics =d>=d>=d>=d>=d>nice Job.....

  8. #8
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  9. #9
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    thanks bill
    nice and very detailled installation there

    im more than glad i took on the task of making these, otherwise i'd had never known my own tunnel was cracked itself maybe my next time out my tunnel would had completly cracked and something terrible could've happen. so i strongly advice to anyone that hasn't reinforced yet to go ahead and do it, wether its with my reinforcement, or home made, however, but reinforce that weak link of the gpr to prevent an accident, serious damage to ski, or sink
    thanks, jorge

  10. #10
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    bill, very nice write up.

    coco, very nice part.

    Q: cutting/milling brackets- I would suggest removing as little metal as possible. Bill, from your final install pics it looks like the left side just had the rear corner knocked off. Do you have a good starting point for removing material?

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