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  1. #1
    ryand's Avatar
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    Virage TXI Cracks

    I recenlty pulled my engine for a rebuild, after cleaning the inside of the hull i noticed some cracks along the gussets under the engine. Attached are photos, a chunk is missing from one of them also. Anything to be worried about?
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  2. #2
    Bernie's Avatar
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    At the back of the Fuel tank near the engine mount right and left side .Yep it is something to worry about your hull is cracked /shattering .Look underneath and you will see that the cracks are just starting to be seen .You can push it with your palm of your hand ,it will move .Clean it all out and grind the raised hubs away .You will need to get some repair material and fill the whole area .Smooth it all over the bottom of the hull make it about 3/4 inch thick .All my ski's did this by 150 hrs .Then you will have no more problems
    Al it has taken 5 yrs for someone else to have this happen (remember PWC days)
    Cheers
    Bernie

  3. #3
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by ryand View Post
    I recently pulled my Virage engine for a rebuild, after cleaning the inside of the hull I noticed some cracks along the gussets under the engine...
    2002 Virage TXi - correct?
    How many hours on the hull?

    Any idea what the previous owners typical riding conditions (smooth water, ocean, wave jumping) were?

    Can you detect cracking or flexing on the outside of the hull in that area?

    You first saw this hull with the engine out, then the shop put it back together for you?
    I wonder if the repair shop knew about the cracking?
    Last edited by K447; 05-04-2008 at 08:16 AM. Reason: Remembered that this is new owner for this Virage

  4. #4
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by Bernie View Post
    At the back of the Fuel tank near the engine mount right and left side. Yep it is something to worry about your hull is cracked /shattering. Look underneath and you will see that the cracks are just starting to be seen. You can push it with your palm of your hand, it will move...
    ...it has taken 5 yrs for someone else to have this happen...Bernie
    Bernie, you lead the way!

    The Virage hulls are single layer - no inner liner - correct?

    The cracking in the photos seems to affect every rib from the fuel tank rearwards. I wonder how far back this hull's damage extends?

    For those Virage hulls that have not yet failed in this manner, should we do some reinforcing now, or just wait until things progress?

  5. #5
    ryand's Avatar
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    Quote Originally Posted by K447 View Post
    Which Virage model, which year?
    How many hours on the hull?

    Any idea what the typical riding conditions (smooth water, waves, ocean, jumping) were?

    Can you detect cracking or flexing on the outside of the hull in that area?
    I can not feel any movement form the outside and i can not see any cracks at all. I dont know how the boat was ridden in the past, im sure from the looks of things it was ridden hard. I am not sure i understand what bernie recomends....Grinding out the gussets and filling the enire bottom with resin and cloth?

  6. #6
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by ryand View Post
    I can not feel any movement form the outside and I can not see any cracks at all. I don't know how the boat was ridden in the past, I'm sure from the looks of things it was ridden hard.

    I am not sure I understand what Bernie recommends....Grinding out the gussets and filling the entire bottom with resin and cloth?
    Bernie runs a PWC rental business in Australia. Ocean riding, lots of hours rapidly accumulated on the hulls and engines.

    Bernie was in the (painful) lead at that time regarding what can fail on the injected Virages, and hull flexing and cracking was one of the issues he experienced.

    Up to now, it seemed to only be an issue with high hour hulls, ridden in rough conditions. If yours is a low hour hull, that will be of real interest to the other Virage TXi owners, like myself.

  7. #7
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by Bernie View Post
    ...Clean it all out and grind the raised hubs away. You will need to get some repair material and fill the whole area. Smooth it all over the bottom of the hull make it about 3/4 inch thick.
    All my ski's did this by 150 hrs...
    Bernie, do you happen to have any photos of a properly done repair on a Virage hull?

  8. #8
    ryand's Avatar
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    Who knows....i was told that the ski had low hours less than 100, but after looking closley at some of the componets...it think it will probably have more than that. If you have ever ridden lake of the ozarks in missouri, it is just like an ocean on the weekends white caps and all. It is very choppy water. So what berrnie is suggesting i do is all inside the hull correct? Bernie please clarify.

  9. #9
    Lake Mead Bum & BTLS Mark starflight's Avatar
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    What material is the virage hull made of? SMC? If so, it's recommended to use epoxy resin and fiberglass cloth.

  10. #10
    Click avatar for tech links/info, donation request K447's Avatar
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    Quote Originally Posted by starflight View Post
    What material is the Virage hull made of? SMC?
    If so, it's recommended to use epoxy resin and fiberglass cloth.
    2002 Virage/Freedom hull materials (all models);
    Hull Material: SMC (Sheet Molded Compound)
    Upper Deck: Fiberglass Reinforced Composite)

    From the Polaris 2002 Service Manual (page 6.19)
    SMC is an epoxy based, rigid, reinforced material.
    Two part rigid structural adhesive (3M 08101 or equivalent) is recommended.
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