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kiteklan
12-30-2009, 11:09 AM
Hello,I will post my renovation experince under this threat.
I am renovating a mastercraft prostar 190 1997 model.
Started with a mistreated hull and without an engine.
I had bought a steyr 236 HP diesel engine with 4200RPM and 2:1 ZF 45 transmission.
Engine weighs 380kg with the transmission.

We built the treyler on our own with Knott axels/parts and I and U profiles.

Please tell me some hints or your opinions.

http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54074&stc=1&d=1262042213

http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54075&stc=1&d=1262042277


http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54076&stc=1&d=1262042400

AFTER SANDPAPER AND POLISH

http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54077&stc=1&d=1262042494

kiteklan
12-30-2009, 11:15 AM
4200 RPM 236 Horse Power Steyr 236 Engine 380 kg with the transmission
I have one propeller right now with a diameter 36cm but I guess it will not be enough,my plan is to lunch the boat with this propeller and get the draft and waterline with the engine,I have no idea about its draft and waterline and the total weight that is why ordering a propeller will not be wise without a certain measurement.

I about the trailer ,rims are from one of my old car (1989 Probe GT),I will try to get it lower and adjust the axels to the center of weight when I will finish the boat.
It is not easy to this work in Turkey since original parts are not easy to find and expensive.
http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54078&stc=1&d=1262042607
Platform after some work
http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54120&stc=1&d=1262159200
Interior Condition Chaos :)
http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54122&stc=1&d=1262159370

kiteklan
12-30-2009, 11:16 AM
Instrument Panel,
http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54124&stc=1&d=1262159480

Original panel was in very bad condition ,we had covered it Fiberglass and make new holes for guages.

I was thinking to use Volkswagen Marine 225 V6 but it was above my budget.Steyr 236 is a light weight and powerfull engine but its dimensions are bigger then orginal mastercraft engines.

Does anyone has an idea how much an orignal mastercraft engine weighs(total weight with transmission? and RPM ,Transmission ratio?

There are more pictures on the my website

DemolitionMan
12-30-2009, 11:21 AM
Looking Good.:)

thatsmrmastercraft
12-30-2009, 11:26 AM
I am really interested in how that diesel performs in the boat.

Definitely making progress. Keep up the good work!

kiteklan
12-30-2009, 11:52 AM
Today we name the boat:

kiteklan
12-30-2009, 11:54 AM
thanks ,I am trying to finish it in 2 weeks.

rholmes
12-30-2009, 02:07 PM
The motor should weigh 227-272 kilograms fully dressed. A transmission was likely originally a hurth 1:1 and would have weighed probably in the neighborhood of 68 kilos. Operating RPM range would have been about 600rpm to a max of 4600-5000rpm. These are just rough figures, nothing exact. maybe someone else can help out with exact numbers.

jasonba1
12-30-2009, 04:52 PM
awesome project

JLeuck64
12-30-2009, 05:10 PM
Just a guess... but I think you will be disappointed with the boats performance if you go to all the trouble of making that engine combination fit. It looks like it is only a four cylinder engine in the photo.

4200 RPM 236 Horse Power Steyr 236 Engine 380 kg with the transmission
I have one propeller right now with a diameter 36cm but I guess it will not be enough,my plan is to lunch the boat with this propeller and get the draft and waterline with the engine,I have no idea about its draft and waterline and the total weight that is why ordering a propeller will not be wise without a certain measurement.

I about the trailer ,rims are from one of my old car (1989 Probe GT),I will try to get it lower and adjust the axels to the center of weight when I will finish the boat.
It is not easy to this work in Turkey since original parts are not easy to find and expensive.
http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54078&stc=1&d=1262042607
Platform after some work
http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54120&stc=1&d=1262159200
Interior Condition Chaos :)
http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54122&stc=1&d=1262159370

Jerseydave
12-30-2009, 06:39 PM
Just a guess... but I think you will be disappointed with the boats performance if you go to all the trouble of making that engine combination fit. It looks like it is only a four cylinder engine in the photo.

I disagree to some extent.......diesels do take longer to "spool up" so the 0-36 mph time will suffer, but it should "hold" speed rather well (good for slalom), get 2-3 times the fuel economy of a gas V-8 and last much longer too. It would be a great engine choice in a wakeboard boat (heavy, ballast). I know diesel is the way to go for alot of reasons in europe.

Did you consider a 5.7 liter V-8 powered by propane? I know that's a good combo in europe as well.

BTW, that gelcoat is looking good! :D 2-week project? That's awesome! Looking forward to the pics as things progress.

Carpe Diem! :)

thatsmrmastercraft
12-30-2009, 08:08 PM
I disagree to some extent.......diesels do take longer to "spool up" so the 0-36 mph time will suffer, but it should "hold" speed rather well (good for slalom), get 2-3 times the fuel economy of a gas V-8 and last much longer too. It would be a great engine choice in a wakeboard boat (heavy, ballast). I know diesel is the way to go for alot of reasons in europe.



Thats also a rather high RPM diesel, so perhaps the spool up time will be lessened somewhat.

On the positive side, diesels have tremendous low end torque so that may have some hole shot assistance.

kiteklan
12-31-2009, 03:29 AM
Just a guess... but I think you will be disappointed with the boats performance if you go to all the trouble of making that engine combination fit. It looks like it is only a four cylinder engine in the photo.

Can't say anything before finding the exaxt prop and testing it in the sea
Transmission ratio is 2:1 which is not good that is I know but I will try to find a big prop with a high pitch.Other then that the engine is a 6 cylinder 3.2 liter gives max 440 Nm Tork at 3300 Rpm.
I atttached the engine data in Pdf.

440 NM = 324.48 Lb/Ft is what this engine produces.


RTP engine 310 HP 360 ft.lb. (488NM)
MCX engine 350 HP 380 ft.lb.(515NM)
VW TDI 225HP 335 lb (454NM)
1 foot-pound is closely equivalent to:1.3558179483314 newton meters

I think in respect to fuel economy and performance ,overall we will get a 4/5.

Thanks for the comments.

kiteklan
12-31-2009, 03:47 AM
I disagree to some extent.......diesels do take longer to "spool up" so the 0-36 mph time will suffer, but it should "hold" speed rather well (good for slalom), get 2-3 times the fuel economy of a gas V-8 and last much longer too. It would be a great engine choice in a wakeboard boat (heavy, ballast). I know diesel is the way to go for alot of reasons in europe.

Did you consider a 5.7 liter V-8 powered by propane? I know that's a good combo in europe as well.

BTW, that gelcoat is looking good! :D 2-week project? That's awesome! Looking forward to the pics as things progress.

Carpe Diem! :)

Nj,It took about 2 months to find this engine,those engines are not still show up in the 2nd hand market,this engine was at 600hr and year 2002 that is why we chose it.
For the progress check the pictures :).

Name Stickers were for registration,we will work on something look nice with decals .

kiteklan
12-31-2009, 03:59 AM
http://www.indmar.com/ProductLine/Indmar/Steyr-256/index.html

Inmar is using the same engine with 256HP,mine is 236.

JLeuck64
12-31-2009, 04:29 AM
I am pulling for ya! Hope you can make that combination work with some trial and error in the prop selection.

Can't say anything before finding the exaxt prop and testing it in the sea
Transmission ratio is 2:1 which is not good that is I know but I will try to find a big prop with a high pitch.Other then that the engine is a 6 cylinder 3.2 liter gives max 440 Nm Tork at 3300 Rpm.
I atttached the engine data in Pdf.

440 NM = 324.48 Lb/Ft is what this engine produces.

RTP engine 310 HP 360 ft/lb (I think this should be Lb/ft but MC site uses as it)
MCX engine 350 HP 380 ft/lb
VW TDI 225HP 335 ft/lb

I think in respect to fuel economy and performance ,overall we will get a 4/5.

Thanks for the comments.

kiteklan
12-31-2009, 05:03 AM
JLeuck,I am really not sure about the end result,but made comparison with the figures above.I will post all the results here.

kiteklan
12-31-2009, 09:50 AM
Check out the pictures.

JohnE
12-31-2009, 09:57 AM
Wow, looks great.

markismm
12-31-2009, 10:13 AM
Very interesting using a turbo diesel in that boat. Do you think that the turbo is going to stay cool enough not to melt the engine box? I'll bet you can swing a rather large prop with a high pitch with that torqy motor. Do you know what the motor came out of?

kiteklan
12-31-2009, 11:25 AM
Very interesting using a turbo diesel in that boat. Do you think that the turbo is going to stay cool enough not to melt the engine box? I'll bet you can swing a rather large prop with a high pitch with that torqy motor. Do you know what the motor came out of?

It is an orginal Marine Engine(Steyr 236) not a converted one and taken out of Power Boat.
About the Turbo,it is double wall water called,which means there is shell outside the turbo which fresh water is cooling.Most of the Turbo Diesel marine engines has it.Fresh water is cooled by the sea/lake water.
propeller is still the dark horse. Calculations gives 49mph.

Does anyone know a propeller manufacturer?

cbryan70
12-31-2009, 11:35 AM
will you be able to fit an 18inch prop on that thing? I would get into contact with OJ props or ACME. Both are great and may be able to at least guide you in the right direction. If you call OJ ask for Eric, I beleive he is the owner

C36
12-31-2009, 07:14 PM
Contact information for OJ can be found here:
http://www.ojprops.com/contact_us

JohnnyB
12-31-2009, 08:41 PM
Very interesting project. Keep us all informed with posts as you progress. I think many of us will be interested to understand the performance of the boat with this engine. Also, as you can tell, many here are willing to help brainstorm through issues you run into. Many creative and mechanically talented people on this discussion board.

DemolitionMan
12-31-2009, 08:56 PM
That dash looks great!!!!!!

mig
12-31-2009, 10:44 PM
kiteklan, what a great project. Are you into course skiing? Do you ski behind direct drives? I hope you will be able to compare how the Steyr tows in the course compared to gas engines. Best of luck and keep the updates coming!

kiteklan
01-01-2010, 03:32 AM
Thanks, Never ski behind a direct drive,It will be 1st. time when we finish.
Direct drive is the only reason that I am repairing this boat.Some people say it will be not nice to smell diesel fume,but I am not concerned about it because Steyr is a really clean engine.We will see.

Holman J.B.F
01-01-2010, 06:01 AM
I asume diesel is way cheaper than gasoline in the Turkey.Good thing you find a second hand steyer,...600 hours is nothing for a steyer.
In most countries of europe diesel prices are aprox 25% cheaper than gasoline.Gasmileage on diesels isn,t that great,better than gasoline,but not worth a 20k upgrade.
For now LPG is the way to go,i still can,t believe why LPG is not popular in the u.s.a among skiboat owners and clubs.I see forklift trucks with LPG.
P.s don,t want to hyjack this thread.
Kiteklan if you want parts,just PM we have boxes full of used gauges swiches exhaust silensers flaps perfect pass parts props etc etc.
If you have questions you might try paul fong,s skischool in singapore he has the same setup for years,over 5000 hours.good luck.

kiteklan
01-01-2010, 08:46 AM
Thanks Holman,That is correct diesel is cheaper and thanks for the information about the parts,I will contact with you.I see your website and got your contact details.
Can you PM me the Paul's email.?

TRBenj
01-01-2010, 12:34 PM
Very interesting project!

Calculations gives 49mph.

I think thats overly optimistic. You should find that the slip percentage will be in the range of 15-20% at best. The smaller, lighter, smaller wetted surface inboards Ive dealt with tend to run closer to 15%, while the newer slalom machines tend to run closer to 20%. You may be looking at a greater slip percentage with that huge reduction trans and super steep prop. If you break 40mph you'll be doing pretty good. Ive seen a few 95-97 Prostars flirt with 50mph, but that's with the 310+ hp V8's.

As far as prop selection goes, that is going to be a major hurdle for you. If you had a gearbox closer to 1:1 (as much as 1.5:1) you could probably find somthing off the shelf that would work- but with a 2:1 and a low RPM motor, youre off the grid for standard ski boat props. You'll want to narrow down your search by looking at props that are 12-14" in diameter- you wont fit anything bigger than that on the boat.

kiteklan
01-01-2010, 06:04 PM
Very interesting project!



I think thats overly optimistic. You should find that the slip percentage will be in the range of 15-20% at best. The smaller, lighter, smaller wetted surface inboards Ive dealt with tend to run closer to 15%, while the newer slalom machines tend to run closer to 20%. You may be looking at a greater slip percentage with that huge reduction trans and super steep prop. If you break 40mph you'll be doing pretty good. Ive seen a few 95-97 Prostars flirt with 50mph, but that's with the 310+ hp V8's.

As far as prop selection goes, that is going to be a major hurdle for you. If you had a gearbox closer to 1:1 (as much as 1.5:1) you could probably find somthing off the shelf that would work- but with a 2:1 and a low RPM motor, youre off the grid for standard ski boat props. You'll want to narrow down your search by looking at props that are 12-14" in diameter- you wont fit anything bigger than that on the boat.

I found a manufacturer ,produces custom props, 4 and 5 blade I will use the original prop (1st photo) for 1st time testing after geting exact weight and measurements of draft and waterline,I am thinking to order a 5 blade.

DemolitionMan
01-01-2010, 06:06 PM
Now that's a prop!!!:)

kiteklan
01-01-2010, 06:10 PM
dont you think it will work with a 2:1 transmission better then a 4 blade.
maybe also a lot of smoke :)

kiteklan
01-02-2010, 02:50 AM
http://www.youtube.com/watch?v=0v9PeQ8FRoc

I added a video on the youtube.

kiteklan
01-02-2010, 09:22 AM
Today,we had received new covered seats and Interior and it is ready to install.
We still have the electrical work and the carpet issue.

kiteklan
01-02-2010, 09:30 AM
Today we had lifted the boat with the interior and without the fuel tank.It weigh 1040kg ,2288 pounds. It think the final dry weight will be around 1300kg ,2860 pound.
How much an orginal mastercraft weighs?

mark g
01-02-2010, 09:58 AM
just had a look through it reads as having a weight of 2450 pounds
link to article below history of mastercraft
http://www.mastercraft.com/teamtalk/showthread.php?t=29236

Sodar
01-02-2010, 12:56 PM
WOW!! Where did that interior color scheme come from!?!? Isn't the exterior purple and grey?

TRBenj
01-02-2010, 04:10 PM
I found a manufacturer ,produces custom props, 4 and 5 blade I will use the original prop (1st photo) for 1st time testing after geting exact weight and measurements of draft and waterline,I am thinking to order a 5 blade.
A 5-blade would be interesting... what does a custom prop cost?

Did you reverse the picture that showed the original prop? It shows a RH prop, which wouldnt have been original.

DemolitionMan
01-02-2010, 04:24 PM
WOW!! Where did that interior color scheme come from!?!? Isn't the exterior purple and grey?

I don't know where it came from but I like it. :)

jasonba1
01-02-2010, 05:00 PM
that is a awesome project looking great cant wait to see the finished product

thatsmrmastercraft
01-02-2010, 08:44 PM
Great progress. The replacement interior looks great. Have you decided on exterior graphics yet?

kiteklan
01-03-2010, 03:01 AM
WOW!! Where did that interior color scheme come from!?!? Isn't the exterior purple and grey?

I don't know where it came from but I like it. :)

interior scheme is red(light)/grey white,exterior still the original.Did not have so much time on schema ,only selected the colors and gave it to the craftsman.He did a good job.

kiteklan
01-03-2010, 03:08 AM
Thanks for the comments,I am thinking to get the originals reproduced(I took some photos before sand paper,what I am thinking is finding a local printshop and get these graphics printed with waterproof ink on a film.
Also thinking to purchase new ones from U.S which I found some on the net on different stores.See the examples.

kiteklan
01-03-2010, 03:16 AM
A 5-blade would be interesting... what does a custom prop cost?

Did you reverse the picture that showed the original prop? It shows a RH prop, which wouldnt have been original.

That is correct it is RH ,it was on the boat .I get it balanced and cleaned. Can somebody tell me a quick way of calculating the pitch of this prop?

kiteklan
01-03-2010, 03:19 AM
About the cost of prop,still not get the offer,think I will get it on monday or tuesday.I will tell you when I get it.

scott023
01-03-2010, 03:42 AM
Cripes that has come together quickly... nice work.

JLeuck64
01-03-2010, 04:20 AM
They usually just stamp the pitch and diameter on the hub somewhere. That looks like it could just be a 13 X 13 (13 inch pitch X 13 inch diameter)

Really should get Eric at OJ in your corner on propping this boat! I hear his customer service is outstanding...

That is correct it is RH ,it was on the boat .I get it balanced and cleaned. Can somebody tell me a quick way of calculating the pitch of this prop?

Hoosier Bob
01-03-2010, 02:22 PM
That thing is BAD A**! I would love to hear it coming down the river. Diesel rules! Do you guys gave a displacement tax on boats? 5.7 being huge penalty in some countries from what I have heard. Awesome job cannot wait to hear how she goes!

DemolitionMan
01-03-2010, 02:32 PM
Thanks for the comments,I am thinking to get the originals reproduced(I took some photos before sand paper,what I am thinking is finding a local printshop and get these graphics printed with waterproof ink on a film.
Also thinking to purchase new ones from U.S which I found some on the net on different stores.See the examples.

The red will look good.:)

kiteklan
01-03-2010, 08:30 PM
That thing is BAD A**! I would love to hear it coming down the river. Diesel rules! Do you guys gave a displacement tax on boats? 5.7 being huge penalty in some countries from what I have heard. Awesome job cannot wait to hear how she goes!
actually boats taxed here with the lenght not with the engine.a 22 feet boat taxed same if it has a v8 or anyother engine.It is the gas price which is very expensive.

Hoosier Bob
01-03-2010, 10:13 PM
Sounds like you are good on both counts then! Very cool! Can't wait to see it running!:Dactually boats taxed here with the lenght not with the engine.a 22 feet boat taxed same if it has a v8 or anyother engine.It is the gas price which is very expensive.

kiteklan
01-04-2010, 12:10 PM
Today we had finished the electrical work of the dashboard,ignition,black guages and red lights are from the orginal steyr engine panel .White spedo meter ,voltmeter and fuel guage are Faria brand marine stuff. By the way faria is working with original level instrument on the fuel tank.
Our Mechanic Halit Altunsöz and the Electrician Adem are holding the board.

kiteklan
01-04-2010, 12:24 PM
We are going to lunch this boat for prop test and draft measurements this weekend.
To tell you the truth ,I can not say this boat is going to be an orginal mastercraft but a functional one.If I would live in the U.S. ,I would do everythin to purchase the orginal parts and the engine but also in that case it would take months to get everyting in line.

thatsmrmastercraft
01-04-2010, 01:21 PM
You are doing an incredible job putting together a very functional boat. Given your circumstances, I see very little reason not to be completely satisfied with your progress and what should be a very serviceable tow boat.

I am very intrigued by the engine choice, and look forward to hearing how your water test goes.

kiteklan
01-04-2010, 01:58 PM
A 5-blade would be interesting... what does a custom prop cost?

Did you reverse the picture that showed the original prop? It shows a RH prop, which wouldnt have been original.

Spoke with the manufacuter of the 5 blade prop,unfortunately they do not have anything under 18" but he has a 16" diameter 4 blade 23" pitch.Cost of prop is about 600-700 USD.
I will also contact with OJ today.

TRBenj
01-04-2010, 03:54 PM
Spoke with the manufacuter of the 5 blade prop,unfortunately they do not have anything under 18" but he has a 16" diameter 4 blade 23" pitch.Cost of prop is about 600-700 USD.
I will also contact with OJ today.

Id be surprised if you could physically mount anything larger than a 14" prop. Cutting down a 16" prop would be pretty drastic.

I agree with your course of action- testing the original prop as a baseline before buying a new one, that is. That RH prop isnt original though- you need a transmission that either reverses the direction of engine rotation or a reverse rotation engine to turn a RH prop on a direct drive. Not sure what engine was in the boat before, but the original engine wouldnt have swung a RH prop. Unless your new powerplant spins opposite the conventional rotation or the tranny can be reversed, you may need a new prop to water test it.

DemolitionMan
01-04-2010, 04:03 PM
Man you are turning and burning. Keep up the good work.:)

EJ OJPROP
01-04-2010, 04:08 PM
I found a manufacturer ,produces custom props, 4 and 5 blade I will use the original prop (1st photo) for 1st time testing after geting exact weight and measurements of draft and waterline,I am thinking to order a 5 blade.

Has the shaft in the picture been removed from the transmission coupler? If not then I would suggest a shorter shaft, getting the prop closer to the strut and away from the rudder. A distance of 1/2" to 3/4" from the strut to the propeller hub is safe. I don't think you can run much more than 14.75" diameter prop on that set up. The 2.0 gear is tough to prop without the room for diameter.

cbryan70
01-04-2010, 04:11 PM
well there you have it

kiteklan
01-04-2010, 04:23 PM
prop on the boat is not the original for sure the gearbox 2:1 ZF45A came with the engine(it was mounted on it) ,I think if I would have a 1.25:1 or 1.5:1 then I would have no problems finding a suitable prop.
Now I will try to find out if I can buy parts of the transmission to decrease the ratio and what will it cost?

The Clear distance of the prob:
42 cm is the clear distance of the prop when the shaft is mounted.there is still 3.5cm gap between the prop and the hull.

kiteklan
01-04-2010, 04:30 PM
Has the shaft in the picture been removed from the transmission coupler? If not then I would suggest a shorter shaft, getting the prop closer to the strut and away from the rudder. A distance of 1/2" to 3/4" from the strut to the propeller hub is safe. I don't think you can run much more than 14.75" diameter prop on that set up. The 2.0 gear is tough to prop without the room for diameter.

Wouldn't we have better performance if we had a 1.5:1 or 1.25:1 ?

EJ OJPROP
01-04-2010, 04:41 PM
Wouldn't we have better performance if we had a 1.5:1 or 1.25:1 ?

Yes you would and more options for props.

kiteklan
01-04-2010, 04:48 PM
do you think 2:1 bring any advantage if I can find the right prop?

ski_king
01-04-2010, 05:10 PM
Eric, I am going to guess that a 478 would be your closet stock prop to meet his needs? (assuming the direction is correct)



By the way, nice project! Keep up the good work.

kiteklan
01-04-2010, 05:16 PM
PART #478 14.5 X 23 LC 1 1/8" 4-BLADE .110 CUP is this your suggestion?

ski_king
01-04-2010, 05:22 PM
NO, I am not a prop expert, it is just my guess. Let Eric recommend a prop.

PART #478 14.5 X 23 LC 1 1/8" 4-BLADE .110 CUP is this your suggestion?

EJ OJPROP
01-04-2010, 05:50 PM
The 14.5 X 23 is the highest pitch prop we currently make. Have to start somwehere and that would be as good as any for a baseline. The only problem is the rotation, it is Left Hand and not available in Right Hand.

TRBenj
01-05-2010, 12:03 PM
The 14.5 X 23 is the highest pitch prop we currently make. Have to start somwehere and that would be as good as any for a baseline. The only problem is the rotation, it is Left Hand and not available in Right Hand.
Does he need RH or LH? Unless Ive missed it, he hasnt answered the question as to which direction the engine/transmission rotates.

Also, is the boat set up for a 1" or 1-1/8" shaft? The 1:1 MC's came with a 1", correct? Im guessing he'll want to measure his shaft and/or strut and shaft log to be safe.

The 2:1 will probably come out of the hole great if you can prop it correctly. Thats the advantage that the reduction drives (1.25-1.5:1) have over the 1:1. Top speed will not be its strong suit, though. Larger reductions like the 2:1 are commonly used on larger boats (that need help getting out of their own way)... tugboats, etc. Ive never heard of anything that large on a ski boat.

kiteklan
01-05-2010, 12:12 PM
ZF45A transmission works both ways ,it is not important RH or LH ,they both work.Transmission forward and reverse is identical.

kiteklan
01-05-2010, 12:41 PM
Today we finished the electrical and start the engine.We did not give full power since engine is running new.
Listen you will like it :)

Sodar
01-05-2010, 12:45 PM
That turbo spooling up sounds so cool!

Jorski
01-05-2010, 12:49 PM
Need a video of the boat running! I can't believe how quickly, you have gottent this together!

kiteklan
01-05-2010, 12:53 PM
cant upload the video file here,so now it is youtube:
http://www.youtube.com/watch?v=4vSn7wd0yJc

it was dark when we test it.
Tomorow I can show it to you online if you want
we are at the +2 GMT zone.The time is here 18:58 now.

Just uploaded the video allow 15minutes so youtube can process.

EJ OJPROP
01-05-2010, 01:20 PM
ZF45A transmission works both ways ,it is not important RH or LH ,they both work.Transmission forward and reverse is identical.

That makes life easier prop wise. What is the diameter of the shaft?

kiteklan
01-05-2010, 01:24 PM
I will upload a clear movie tomorrow.

kiteklan
01-05-2010, 01:25 PM
That makes life easier prop wise. What is the diameter of the shaft?

the shaft size is 31mm

rob935
01-05-2010, 01:42 PM
very keane to see how the boat performs in the water , i would love to convert my prostar to diesel as we can use agri diesel in ireland which is half the price of petrol which means twice the water time for the same cost .......cant believe the speed of your progress , well done so far .

kiteklan
01-05-2010, 02:29 PM
very keane to see how the boat performs in the water , i would love to convert my prostar to diesel as we can use agri diesel in ireland which is half the price of petrol which means twice the water time for the same cost .......cant believe the speed of your progress , well done so far .

Thanks,saturday or sunday this boat will be on the water for test run then we will see how it performs ,I am also very curius about it.

thatsmrmastercraft
01-05-2010, 02:36 PM
Your diesel sounds fantastic. Gotta love the turbo spooling up.

Thrall
01-05-2010, 04:26 PM
This is a great project!
I'm excited to hear how it runs for you.
Good job so far. You should be very proud of this rebuild!

markismm
01-05-2010, 10:31 PM
Definitely unique and cool at the same time. One of the best things is that you can change the performance of that motor a great deal by simply changing the amount of boost or by installing a larger turbo. Can't wait to see how it performs on the water. Do you already have a prop to test the boat with? If so, what are the measurements?

kiteklan
01-06-2010, 04:16 AM
Definitely unique and cool at the same time. One of the best things is that you can change the performance of that motor a great deal by simply changing the amount of boost or by installing a larger turbo. Can't wait to see how it performs on the water. Do you already have a prop to test the boat with? If so, what are the measurements?

test will be on saturday or sunday.We will use the propeller on hand and we only know the diameter which is 36cm,pitch unknown.

kiteklan
01-06-2010, 05:42 AM
One issue I had stucked is these decals and have no idea what to put on the boat,I hope some can help me to sort this out and give me design and ideas.I had attached a most recent photos of the boat ,you know it is a 1997 Prostar and what I think would look nice on the boat are the orginal decals.I had found a few sites on the net but have no idea about the original dimensions of these decals and where to source them without paying a fortune.
Please give me some ideas.I also need the the name of the boat and a graphic to be printed with the same style.

http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54132&stc=1&d=1262188344

And to write somewhere on the boat that the boat
"powered by Steyr 236 Diesel"

Do you know anyone who can help to get a total solution?

Chicago190
01-06-2010, 01:35 PM
Send a PM or search for the user Farmer Ted. He is a member on this site and does vinyl graphics.

I also vote no name. I think that naming a ski boat is stupid.

Other than that, great work on the project.

C36
01-06-2010, 08:28 PM
1997 MasterCraft Brochure can be downloaded by clicking here (http://www.mediafire.com/?9mkzti1k2gw).

There are some dimensions to 1997 decals found in a table by clicking here (http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=51074&d=1251496782).

The decals shown in the table can be viewed by clicking here (http://www.mastercraft.com/teamtalk/showthread.php?t=21104).

Farmer Ted (as Chicago190 mentioned) would be a good place to start. But his website seems to be under construction right now. You can contact him by clicking here (http://www.mastercraft.com/teamtalk/member.php?u=27). Then click on "contact info".

One issue I had stucked is these decals and have no idea what to put on the boat,I hope some can help me to sort this out and give me design and ideas.I had attached a most recent photos of the boat ,you know it is a 1997 Prostar and what I think would look nice on the boat are the orginal decals.I had found a few sites on the net but have no idea about the original dimensions of these decals and where to source them without paying a fortune.
Please give me some ideas.I also need the the name of the boat and a graphic to be printed with the same style.

http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54132&stc=1&d=1262188344

And to write somewhere on the boat that the boat
"powered by Steyr 236 Diesel"

Do you know anyone who can help to get a total solution?

Hoosier Bob
01-06-2010, 10:57 PM
Hey MC send him some decals! This is possibly the coolest thread here! IMO!:D

Barefooter92
01-06-2010, 11:51 PM
Great project. What a vision and tremendous skill to make it happen. You should be very proud of this project. You need to see how many deep water barefooters it will pull. If you need bodies to drag I'll be one of them!

kiteklan
01-07-2010, 12:40 AM
Great project. What a vision and tremendous skill to make it happen. You should be very proud of this project. You need to see how many deep water barefooters it will pull. If you need bodies to drag I'll be one of them!

It is really great to see that there are a lot of people sharing and motivating.Your support is making definetly things easier.Thank you so much.

The boat is in Turkey ,near the south cost in a city named mersin (60 km west of Adana) where we have lakes and great beachs.

Barefooter92 you are always welcome.

kiteklan
01-07-2010, 12:03 PM
Today we had lined up the engine,work on the engine mounts and finished the engine line-up allingnment,also ordered a flexible coupling between the shaft and the gearbox for a smoth operation on the gear changes forward to Neutral to Reverse.

rob935
01-07-2010, 02:17 PM
looks fantastic ...cant wait to hear how it performs on the water , this has to be the most intersting post ive seen on teamtalk yet , no offence to anybody else but this project is just so different .

kiteklan
01-08-2010, 01:17 AM
1997 MasterCraft Brochure can be downloaded by clicking here (http://www.mediafire.com/?9mkzti1k2gw).

There are some dimensions to 1997 decals found in a table by clicking here (http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=51074&d=1251496782).

The decals shown in the table can be viewed by clicking here (http://www.mastercraft.com/teamtalk/showthread.php?t=21104).

Farmer Ted (as Chicago190 mentioned) would be a good place to start. But his website seems to be under construction right now. You can contact him by clicking here (http://www.mastercraft.com/teamtalk/member.php?u=27). Then click on "contact info".

David thank you for your support.

kiteklan
01-08-2010, 06:17 AM
Took some pictures from the Exhaust.It is not stainless steel since we will paint it with zink-phospate and epoxy last coat.

kiteklan
01-08-2010, 06:23 AM
Can someone tell me what is the purpose of this small plastic tank over the fuel tank.?

kiteklan
01-08-2010, 08:43 AM
We are ready for tomorrow lunching the boat check the video for engine running and the last voice.

Tomorrow we will install the remote control and a few small things to finish.

I hope we will send you the video on water tomorrow.

http://www.youtube.com/watch?v=eSko-oaY9_0

thatsmrmastercraft
01-08-2010, 10:01 AM
You certainly have a lot of people on this forum very interested in your project. Definitely looking forward to your water test. Good luck.

mayo93prostar
01-08-2010, 10:05 AM
I suspect that small tank is a fuel overflow catch tank but I have never seen one on a boat here in the US.

Finnsdad
01-08-2010, 10:49 AM
I cant wait to see it in the water!

kiteklan
01-08-2010, 11:35 AM
looks fantastic ...cant wait to hear how it performs on the water , this has to be the most intersting post ive seen on teamtalk yet , no offence to anybody else but this project is just so different .

Rob ask where can he source diesel engines.I had a long search before buying steyr.There are several brands/models "VW 225" or "FNM HPE 250" italian fiat ,Steyr 236,246 or 256 ,Iveco and also Volvo D3 190 . These are suitable engines all around 18k-20k(new ones) in my country but I am sure they will cost rest in europa and U.S. I bought 2nd hand but an engine at 550 hr. 2002 it was quite new model sourced with friends network who is in marine/boats business.Had a long period about 3 months taking the decision and buying it.
For finding a 2nd hand engine you can follow used boat classified sites and forums.
I think you have better chance to find steyr since it is in market for many years others are quite new so still did not show up in the 2nd hand market.

I think steyr is the best weight/power with 256 model and simplicity.

point1234
01-08-2010, 12:37 PM
I love this keep up the good work. My father has a Duramax diesel truck, just love the sound of a diesel running and the turbo spooling up.

TRBenj
01-08-2010, 04:43 PM
also ordered a flexible coupling between the shaft and the gearbox for a smoth operation on the gear changes forward to Neutral to Reverse.
I really wouldnt recommend installing this. We had one on one of our boats (came installed when we bought it) and it performed much better once we removed it. Its really a band-aid some people put on to hide misalignment.

The damper plate that resides between the engine and transmission is all you need... it will be smooth as silk compared to any outboard or I/O.

kiteklan
01-08-2010, 04:47 PM
I really wouldnt recommend installing this. We had one on one of our boats (came installed when we bought it) and it performed much better once we removed it. Its really a band-aid some people put on to hide misalignment.

The damper plate that resides between the engine and transmission is all you need... it will be smooth as silk compared to any outboard or I/O.

TR,thanks for the advice,could you send me a photo of that damper plate or a reference?

mig
01-09-2010, 04:55 PM
It is Saturday here kiteklan and I am hoping for some on-the-water utube to watch!

cbryan70
01-09-2010, 05:02 PM
ive been waiting all day

JLeuck64
01-09-2010, 05:37 PM
TR,thanks for the advice,could you send me a photo of that damper plate or a reference?

Here's a pic from the back of my engine. I would assume your engine is already set up this way also. I would just align the engine/trans to the shaft and run with it too!

kiteklan
01-09-2010, 06:11 PM
Here's a pic from the back of my engine. I would assume your engine is already set up this way also. I would just align the engine/trans to the shaft and run with it too!

jLeuck thanks for the pictures,now I understand what you mean ,we have already the original part in between the Steyr and the ZF gearbox,What I am waiting for is the flexible coupling between the gearbox and shaft flange. It is a part like this sits just after the gearbox mounted to the flange and connected to the shaft coupling.

http://www.randdmarine.com/FLEXIBLESC/IMAGES/popdia.gif

http://www.randdmarine.com/FLEXIBLESC/IMAGES/popim.jpg

I need this part also for taking the propeller a little back to the end of the boat so I can use a higher diameter prop.

kiteklan
01-09-2010, 06:18 PM
ive been waiting all day

It is Saturday here kiteklan and I am hoping for some on-the-water utube to watch!

Sorry for that :D
I ordered a flexible coupling and the wrong part show up this morning so our lunch has postponed to Sunday afternoon.The part is coming from 1200km and right now it is on its way to mersin , instead of getting it posted with cargo we go with the old way,asked the supplier to correct his fault and send me the part with a passenger bus coming from Istanbul:).Let's see if I will get the correct part in the morning I will post it here.

cbryan70
01-09-2010, 06:52 PM
and what will this part do? It should not shift hard into gear now with the damper plate.....

kiteklan
01-10-2010, 02:48 AM
and what will this part do? It should not shift hard into gear now with the damper plate.....

Reduces engine noise and vibration coming from the prop .

JohnnyB
01-10-2010, 12:04 PM
anxiously awaiting the results of your maiden voyage....take lots of pictures.

cbryan70
01-10-2010, 12:04 PM
post the video on google videos instead of youtube....dont have acess to youtube at work :-)

kiteklan
01-10-2010, 12:28 PM
it was great just arrive home,It is 18:28 now here.I am working on the post now.

cbryan70
01-10-2010, 01:37 PM
:-) google video lol

JLeuck64
01-10-2010, 01:37 PM
jLeuck thanks for the pictures,now I understand what you mean ,we have already the original part in between the Steyr and the ZF gearbox,What I am waiting for is the flexible coupling between the gearbox and shaft flange. It is a part like this sits just after the gearbox mounted to the flange and connected to the shaft coupling.

I need this part also for taking the propeller a little back to the end of the boat so I can use a higher diameter prop.

Over here we just bolt the flanges together. As long as your align the output flange on the transmission so that is within .003 inches from parallel to the prop shaft flange you will not feel any vibration.

Check this link out:
http://elberts.com/faq.htm#q20

rob935
01-10-2010, 01:56 PM
think we are all online waiting patiently for the post on how the maiden voyage went ......sounds like its time for a drum roll or something ???? hope it went well for you kitelan......

JohnnyB
01-10-2010, 02:22 PM
:popcorn::popcorn::popcorn::popcorn:

_____________________________________

kiteklan
01-10-2010, 02:53 PM
Today we finished the remote control,water inlet and exhaust clamps,The boat was in the harbor after lunch.Our trailer was high so it took a little more time then it should to take the boat down.All was perfect but the prop.We did not push the engine so much since there was no load on it due to the small size of the propeller.Engine was screaming and had a speed about 30miles (easy) with this propeller.
Please check gps data at the link below:

http://sportstracker.nokia.com/nts/workoutdetail/index.do?id=1951993

and the Video is :
http://www.youtube.com/watch?v=1FOudGGAJZg

JohnnyB
01-10-2010, 02:58 PM
What size prop were you running?

JohnnyB
01-10-2010, 03:02 PM
Today we finished the remote control,water inlet and exhaust clamps,The boat was in the harbor after lunch.Our trailer was high so it took a little more time then it should to take the boat down.All was perfect but the prop.We did not push the engine so much since there was no load on it due to the small size of the propeller.Engine was screaming and had a speed about 30miles (easy) with this propeller.
Please check gps data at the link below:

http://sportstracker.nokia.com/nts/workoutdetail/index.do?id=1951993

and the Video is coming...

Too bad you didn't track your heart rate, too.....would've been interesting :D

kiteklan
01-10-2010, 03:02 PM
Over here we just bolt the flanges together. As long as your align the output flange on the transmission so that is within .003 inches from parallel to the prop shaft flange you will not feel any vibration.

Check this link out:
http://elberts.com/faq.htm#q20

It looks really nice,less part less problem.
I will take a photo what we have and post it tomorrow.

kiteklan
01-10-2010, 03:25 PM
What size prop were you running?

Prop had no sign or mark but the diameter is 36cm. pitch 13"(guess of OJ).
My problem is the gearbox which is 2:1 and what I should have 1:1.25 .But had not option since we bought the engine with the gearbox.Anyway I will solve this problem next week.
I found some props around will play a little ,trial and error.Check previous post for details.

kiteklan
01-10-2010, 03:35 PM
Video of 1st test :

http://www.youtube.com/watch?v=1FOudGGAJZg

kiteklan
01-10-2010, 03:38 PM
post the video on google videos instead of youtube....dont have acess to youtube at work :-)

I couldn't access to google videos,try this:

http://www.ktunnel.com

and paste the link

http://www.youtube.com/watch?v=1FOudGGAJZg

kiteklan
01-10-2010, 03:56 PM
I need to hide the stuff under the instrument panel,please send me some photos (if you have), how it is hidden in the original pro star 190.

the steering wheel cables and ect.

rob935
01-10-2010, 03:56 PM
looks very impressive kiteklan ...what was the top speed /acceleration like on it ???

kiteklan
01-10-2010, 04:11 PM
thanks rob,it was around 30mph but we did know that we will not make more before we change the prop.
Acceleration was good but we did not push it to much since it was the first run of this engine this long.
I will re-try with another prop this week.

rob935
01-10-2010, 04:17 PM
sounds great kiteklan , im sure with a few adjustments the performance will improve but 30 mph is ideal for skiing and more than enough pace for wakeboarding ....excellent project and even more impressive time frame , well done .

JohnnyB
01-10-2010, 04:19 PM
Video of 1st test :

http://www.youtube.com/watch?v=1FOudGGAJZg

Thanks for sharing. I would enjoy seeing a video of a full-throttle start to see how quickly it accelerates?

How much water was in the bilge after due to the stuff box and rudder box drip?

What is your intended use for the boat? It appears that you are set up for wakeboarding.

If you get a clearer picture of the underneath of the dash and mark what items you're trying to clean up, I'm sure the folks here can help with that.

Congrats on a successful first voyage.

Chicago190
01-10-2010, 04:49 PM
It's always cool to see a project progress quickly, especially considering how unique this is.

Where was the video shot? Is that fresh water or salt water?

kiteklan
01-10-2010, 04:51 PM
It's always cool to see a project progress quickly, especially considering how unique this is.

Where was the video shot? Is that fresh water or salt water?

Salt water.

Check the link for details:

GPS/Google Map/Statistics
(http://sportstracker.nokia.com/nts/workoutdetail/index.do?id=1951993)

kiteklan
01-10-2010, 04:56 PM
sounds great kiteklan , im sure with a few adjustments the performance will improve but 30 mph is ideal for skiing and more than enough pace for wakeboarding ....excellent project and even more impressive time frame , well done .

Thanks,but I think with a proper prop, it can have a better pull and higher speed.
The engine electronically cut off the RPM since the propeller was so easy turn for it.

kiteklan
01-10-2010, 05:03 PM
We will finish the interior,seats,Music System and carpet.We are also thinking removing one axle from the trailer since it was hard to move when you disconnect from the car on parking.
We will test the boat next Saturday and Sunday with a new prop.

thatsmrmastercraft
01-10-2010, 05:17 PM
Its great to see how well the water test went. I remember how much I enjoyed my first time or two out with my 1977 Mastercraft. I know once I had all the bugs worked out it was even more enjoyable.

Good luck figuring out what prop you need.

Chicago190
01-10-2010, 05:40 PM
Salt water.

Check the link for details:

GPS/Google Map/Statistics
(http://sportstracker.nokia.com/nts/workoutdetail/index.do?id=1951993)

Really cool. I bet you're one of a handful people to take a Prostar out into the Mediterranean Sea (you might be the only). Are the engine and turbo suitable for use in salt water, or will you be installing a closed cooling system in the future?

Edit: the harbor to the East Northeast looks like it would be pretty good for skiing and wakeboarding, although crossing the wake from a 200+ ft. container ship might be a little tricky.

kiteklan
01-11-2010, 03:35 AM
Really cool. I bet you're one of a handful people to take a Prostar out into the Mediterranean Sea (you might be the only). Are the engine and turbo suitable for use in salt water, or will you be installing a closed cooling system in the future?

Edit: the harbor to the East Northeast looks like it would be pretty good for skiing and wakeboarding, although crossing the wake from a 200+ ft. container ship might be a little tricky.

Thanks Chicago, The engine is already a closed system ;works with coolant water inside and it is cooled by sea/lake water in an condenser.
I was very curious about the performance of the prostar but I was not different then another boat at the sea even more stable on the dead waves.

kiteklan
01-11-2010, 04:17 AM
More Video form the 1st Test ,low speed in the harbor.

http://www.youtube.com/watch?v=AyoRt6ePxIk

mig
01-11-2010, 11:22 AM
Thanks for the video and the great thread! Best of luck, hope you get to ski behind it :)

M-Funf
01-11-2010, 02:43 PM
Great project. Nice looking boat. The water is nice...I like that yacht at the end of the video...

C36
01-11-2010, 08:05 PM
Video of 1st test :

http://www.youtube.com/watch?v=1FOudGGAJZg

Glad things went so well - the video was great to see:

the colour of the water
the colour in the sky
the cheer of the people on the dock
the roar of the motor (with the wake flattening out the back of the boat)


... but I have to admit I was a little nervous when I saw the boat being spun around between the two concrete walls at the boat launch!!! :eek: :)

Keep up the good work (and thanks for sharing)!

thatsmrmastercraft
01-11-2010, 08:16 PM
Glad things went so well - the video was great to see:

the colour of the water
the colour in the sky
the cheer of the people on the dock
the roar of the motor (with the wake flattening out the back of the boat)


... but I have to admit I was a little nervous when I saw the boat being spun around between the two concrete walls at the boat launch!!! :eek: :)

Keep up the good work (and thanks for sharing)!

I will second feeling of things clinching up a little, if you know what I mean. Great job so far kiteklan. Obviously that wasn't your first time at the wheel of a boat.

TayMC197
01-12-2010, 02:19 AM
Great work man, Kinda cool seing a project taking place on the otherside of the world.

kiteklan
01-12-2010, 04:19 AM
I will second feeling of things clinching up a little, if you know what I mean. Great job so far kiteklan. Obviously that wasn't your first time at the wheel of a boat.

Glad things went so well - the video was great to see:

the colour of the water
the colour in the sky
the cheer of the people on the dock
the roar of the motor (with the wake flattening out the back of the boat)


... but I have to admit I was a little nervous when I saw the boat being spun around between the two concrete walls at the boat launch!!! :eek: :)

Keep up the good work (and thanks for sharing)!

Great project. Nice looking boat. The water is nice...I like that yacht at the end of the video...

Thanks for the video and the great thread! Best of luck, hope you get to ski behind it :)

Thank you so much for sharing your feelings. I like sharing my experinence at this forum and really suprised how people like their MC and seeing another MC rolling back to water.
About my feelings ,I was very curious about the boats performance and It was my 1st time being on a wheel of the a ski boat but have to admit I was suprized how MC turns on its around.People on the dock was my family and friends(JM) ,the boy talking is my son and lady cheering is my wife.They like it too.All the best.

On the test it was not very confortable since we had no seats (except the passenger) and no cover on the engine that is why it was a little noisy and got some water came out of the hull to bilge in in the begining ,I taste it was fresh so I think it was the water collected from the wash we did inside of the hull.But overall I like it.

This saturday or Sunday we will make another test with all finished and with a different prop
15" 26" pitch 3 blade.

kiteklan
01-12-2010, 04:19 AM
Great work man, Kinda cool seing a project taking place on the otherside of the world.

Thanks Tay :)

kiteklan
01-12-2010, 04:49 AM
Thanks for sharing. I would enjoy seeing a video of a full-throttle start to see how quickly it accelerates?

How much water was in the bilge after due to the stuff box and rudder box drip?

What is your intended use for the boat? It appears that you are set up for wakeboarding.

If you get a clearer picture of the underneath of the dash and mark what items you're trying to clean up, I'm sure the folks here can help with that.

Congrats on a successful first voyage.

JhonnyB you asked how much water was in the bilge,some water came out of the hull but it was fresh ,I guess it was the water collected by rain/wash and so in the hull.About the stuff box and rudder box drip can you explain a little more because I think I had a little salt water coming from the sea but could not find out where it was coming.

hkallestad
01-12-2010, 05:26 AM
Grrreat project! Keep the photos and videos coming! Do you kitesurf as well? Me too;-)

kiteklan
01-12-2010, 08:04 AM
Grrreat project! Keep the photos and videos coming! Do you kitesurf as well? Me too;-)

Thanks yes I do,one of the reasons we are are repairing this boat,for windless days :) you know better then me if you kite.
You can check some of our best kite photos (http://www.kiteklan.org/photo/album/listForOwner?screenName=28ap5razykxxm)

kiteklan
01-12-2010, 08:22 AM
I had sent the prop to a local manufacturer and now have the exact dimensions of the prop we use in the 1st test ,it is 14" diameter and 18.5" pitch prop and we managed to make at 2000 rpm (on the prop/shaft) 28-30 mph with no load on the engine.

kiteklan
01-13-2010, 11:18 AM
We had started to cover carpet in the interior and I am posting what I had found in the market,It is a special carpet with a plastic back and really short fibers allow to fast dry.
Installed a mirror ,not the original but looks good and works.
15m2 is the aprox. required carpet for the whole prostar 190 1997,I bought 12m2 and not covering under the bow.

kiteklan
01-13-2010, 11:23 AM
Finished the electrical of the trailer.

jmcentire
01-13-2010, 06:35 PM
Awesome project!!! Great work kiteklan!!!

cbryan70
01-13-2010, 07:33 PM
you were only at 2000RPM going 30MPH? There will not be a huge difference in the RPM with someone behind the boat. If that motor is made to turn 3500 RPM's you might already have the right prop on it?

shunra
01-14-2010, 02:46 PM
you were only at 2000RPM going 30MPH? There will not be a huge difference in the RPM with someone behind the boat. If that motor is made to turn 3500 RPM's you might already have the right prop on it?

I believe that was 2000prm on the prop shaft. I think he has a 2:1 gearbox so that would put the motor at 4000rpm.

hkallestad
01-14-2010, 03:15 PM
It will be exiting to see what speed he will be able to get with such a massive reduction on the gear.

hkallestad
01-14-2010, 05:55 PM
do you think 2:1 bring any advantage if I can find the right prop?

Acceleration and better ability to hold a stable speed( better torque on the propeller). Top speed will suffer naturally.

kiteklan
01-16-2010, 12:59 AM
you were only at 2000RPM going 30MPH? There will not be a huge difference in the RPM with someone behind the boat. If that motor is made to turn 3500 RPM's you might already have the right prop on it?

I believe that was 2000prm on the prop shaft. I think he has a 2:1 gearbox so that would put the motor at 4000rpm.

It will be exiting to see what speed he will be able to get with such a massive reduction on the gear.

Acceleration and better ability to hold a stable speed( better torque on the propeller). Top speed will suffer naturally.

I found a 16" diameter (it will be reduced to 15.7") and a 28" pitch propeller.Attached are the photos out of the mold,Manufacturer "unlupervane" told me he may be able increase the pitch a little more ,This is the max diameter to install suitable with the 2:1 gearbox.
Otherwise I will sell this gearbox and buy a new 1:1.26.

kiteklan
01-16-2010, 11:24 AM
Carpeting and interior,notice we used stainless steel staples to avoid rusting.

kiteklan
01-16-2010, 11:37 AM
Sunday we will have a test with the new 28" pitch prop.

FrankSchwab
01-16-2010, 12:07 PM
That interior looks great.

Wanna come over to my house and help me with mine? ;)

Great job on this boat; it's amazing how many people appear to be following your progress.

Good luck with the new prop.

/frank

kiteklan
01-16-2010, 03:26 PM
That interior looks great.

Wanna come over to my house and help me with mine? ;)

Great job on this boat; it's amazing how many people appear to be following your progress.

Good luck with the new prop.

/frank

Unlu propellers (http://www.unlupervane.com/index2.asp)

unlupervane hold his promise ,manufactured a 28" pitch prop in one week and send it to me today,I will have it tomorrow morning,I will post some photos as soon as I will receive it.

Thanks for the good wishes.

kiteklan
01-16-2010, 03:43 PM
you were only at 2000RPM going 30MPH? There will not be a huge difference in the RPM with someone behind the boat. If that motor is made to turn 3500 RPM's you might already have the right prop on it?

Cbryan,It is the prop rpm which was 2000 and engine was screaming with the 30mph with no load.I will have a new prop tomorrow,also thinking to test how it performs if I will find some to get ski behind it.

cbryan70
01-17-2010, 03:17 PM
its sunday......

mig
01-17-2010, 09:28 PM
Kitelans latest video - just had to check youtube :) http://www.youtube.com/user/kiteklan#p/a/u/0/R03yBJRbmCE

DemolitionMan
01-17-2010, 09:38 PM
It sound's good. I like the seat cover's.

Ski-me
01-17-2010, 09:46 PM
Although I can't tell how fast they are going or understand a word... it does sound like they are pleasantly surprised with the speed of the boat and new prop! It looks good and congrats on all of your hard work. Look forward to your comments on the actual numbers......

thatsmrmastercraft
01-18-2010, 01:12 AM
Another fantastic installment on kiteklan's project. Looks like you came a lot closer with this propeller. Nice job on the interior. Keep up the great work.

kiteklan
01-18-2010, 05:12 AM
1. 2nd speed test video from inside (http://www.youtube.com/watch?v=R03yBJRbmCE)

2. 3rd Test video from outside (http://www.youtube.com/watch?v=e6wdFAfLR1Y)

3. Long Long Test Video (http://www.youtube.com/watch?v=e-udiUiizqo)

4. Nice Engine Sound /Wake Video (http://www.youtube.com/watch?v=bF0bwSvtfQY)

This time we had the same speed with half rpm,and had a cruise speed about 35mph and a top speed 41mph,but the weather was little windy and tides was high.It was satisfactory to see that this time we had managed to load some on the engine with the new propeller.
If you ever buy a new steyr then it should be 1:1.5 and with this prop, you will be flying.
At this moment ,I am not able to buy a new gearbox so I will accept these figures and use this boat as it is.
on the other hand I would love to try to tow 5-10 guys behind this boat since it has an amazing pull you can feel and see it from the water coloumn behind the boat.

The only thing to be done last is shortening the drive shaft about 0.5-1" to get the prop a little away from the rudder.

I will be posting more videos of the last test during the day so please check out :
All kiteklan videos (http://www.youtube.com/user/kiteklan)

Also some GPS figures of the speed test notice the high speed was in the harbor with Half RPM.
GPS Tracker Info (http://sportstracker.nokia.com/nts/workoutdetail/index.do?id=1976624)

I will make a new test on the lake next sunday.

kiteklan
01-18-2010, 05:24 AM
its sunday......

Kitelans latest video - just had to check youtube :) http://www.youtube.com/user/kiteklan#p/a/u/0/R03yBJRbmCE

It sound's good. I like the seat cover's.

Although I can't tell how fast they are going or understand a word... it does sound like they are pleasantly surprised with the speed of the boat and new prop! It looks good and congrats on all of your hard work. Look forward to your comments on the actual numbers......

Another fantastic installment on kiteklan's project. Looks like you came a lot closer with this propeller. Nice job on the interior. Keep up the great work.

Sorry for late post and thanks for following ,Seat covers has a little work to be done and language next time on the video will be english.We were pleasantly suprised but sea was so tough ( was not expecting this hard).Thanks for the comments please ask if you will have any specific questions ,I will be happy to answer.

By the way accelaration was so good that was the suprizing part.

TMCNo1
01-18-2010, 07:39 AM
I haven't posted yet, waiting for the project to get on the water, but I would like to comment that you are one dedicated soul. You are doing one of the neatest project I've ever seen and I'm amazed as to how much thought, engineering and work you've put into this boat. I'll continue to watch and keep up the great and amazing work!:D Man, that's some rough water!

1redTA
01-18-2010, 11:43 AM
Man, I am really impressed with the short time frame and the amount of work you have completed! That diesel seems like it will work very well for the boat. Keep us updated on the boat especially when you start pulling some people

kiteklan
01-19-2010, 04:18 AM
Actually it was a long one since we had many days with no work done.:D

Skipper
01-19-2010, 09:44 AM
Actually it was a long one since we had many days with no work done.:D

"many days with no work done"...? Sure you don't work for the highway department in the US?

Great work. Very unique build.

coz
01-19-2010, 10:17 AM
I haven't posted yet, waiting for the project to get on the water, but I would like to comment that you are one dedicated soul. You are doing one of the neatest project I've ever seen and I'm amazed as to how much thought, engineering and work you've put into this boat. I'll continue to watch and keep up the great and amazing work!:D Man, that's some rough water!

Indeed.....great job dude! :headbang:

kiteklan
01-19-2010, 11:11 AM
"many days with no work done"...? Sure you don't work for the highway department in the US?

Great work. Very unique build.

Indeed.....great job dude! :headbang:

I am a contractor :) and originally an economist :D

coz
01-19-2010, 11:35 AM
I am a contractor :)


Me too.....how business in Turkey?....it's a dog eat dog, cut throat world for contractors here in the states, at least it is in Az :mad:

kiteklan
01-19-2010, 12:45 PM
Me too.....how business in Turkey?....it's a dog eat dog, cut throat world for contractors here in the states, at least it is in Az :mad:

Actually worse we eat each other alive,tenders are going less %50 of estimated cost.

americanskierJim
01-20-2010, 08:13 PM
I like the boat you did a wonderful job on it. I also like the way the Diesel sounds.

Covi
01-20-2010, 08:45 PM
Kiteklan, Very impressed with the amount of work you have accomplished thus far. Your boat looks great. The diesel sounds awesome. I can't believe how fast you were able to travel in such big surf? How do you kidneys feel? I'm curious on the average outside air temp this time of year? Also one thing I picked up while viewing the long video. The position of the throttle at one point looked like it was in the reverse position while you were traveling forward? Knob appeared to be at a 2 o'clock position and the boat was registering 10 mph. If you were to use reverse gear at what position does the throttle need to be? Keep up the good work!!! I also can't wait to see video of skiers behind that thing!!!!!

kiteklan
01-21-2010, 01:30 AM
Kiteklan, Very impressed with the amount of work you have accomplished thus far. Your boat looks great. The diesel sounds awesome. I can't believe how fast you were able to travel in such big surf? How do you kidneys feel? I'm curious on the average outside air temp this time of year? Also one thing I picked up while viewing the long video. The position of the throttle at one point looked like it was in the reverse position while you were traveling forward? Knob appeared to be at a 2 o'clock position and the boat was registering 10 mph. If you were to use reverse gear at what position does the throttle need to be? Keep up the good work!!! I also can't wait to see video of skiers behind that thing!!!!!

Covi,good points and thanks for the comment.
Old prop was a RH and the new one is LH that is why we did not have time to change the Throttle. about the 2 clock position the Engine has electronic throttle which the lever is connected also if you noticed the interior stucked and stoped the lever in 3/4 reverse position that is why we could not full load.Good thing about the ZF45A transmission (http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=55013&stc=1&d=1264052134) is ;it can work both ways RH or LH gear ratios are the same.
I have no idea where the throttle needs to be :) since we could not load the engine full due to those waves and kidney proplems :).I was also afraid the hit my head somewhere or smash in to the sea.

Temp was around 16 Celcius about 60.8 F ,it was fully cloudy and about to rain.http://weather.msn.com/local.aspx?wealocations=wc:14693.

Next video I will use a HD Cam with good sound recording beleive me it is much better then it sound from video and you can feel the accelaration when you sit.

kiteklan
01-23-2010, 10:59 AM
if the weather allows us we will test the boat on a lake FYI

thatsmrmastercraft
01-23-2010, 11:01 AM
Have you got the throttle situated so you can get full travel now. Of course water conditions permitted.

Always looking forward to hear how the project is coming along.

kiteklan
01-24-2010, 07:20 PM
could not lunch the boat ,it was a very rainy day.hopefully next week.In the mean time made some change on the trailer,romoved one axle since it was to hard to move around and get the trailer lowered about 5",also got a top cover.I will post the photos tomorrow.

kiteklan
02-04-2010, 08:30 AM
sorry for no post for the recent weeks,could not have any chance since the last test to put the boat on water.But in the recent weeks ,I had corrected some problems such as:

Correcting the throttle position on forward
Lowering the trailer by 7"
Removing the 2nd axel from the trailer since it was putting a lot effort to handle it


And the additional works done:

installed a transreducer and a GPS with sonar
installed a 1800 watt apmlifier HiFi and marine speakers
installed a water pump for fresh water/shower
installed a performance air filter on the engine
installed all the accessories hinges and locks
installed a bilge pump


Still to finish:


Water filter
Engine Wash valve in the water inlet
Fuel Filter and Water separator


I will post pictures as soon as I will have time.

thatsmrmastercraft
02-04-2010, 10:32 AM
Sounds like plenty of progress. Many of us are passing the winter by monitoring all the work you are getting done. Keep up the good work.

ski/hunt
02-04-2010, 01:17 PM
Awesome project!!! Just found thread, you've done a great job. I don't have marine gas vs. desiel experience but have owned both in RV's and there is no compare. You may have started something MC devlopers should look into. Years ago in the motocross world 4- stroke motors were not the norm and now they are all the bikes have in them. Who knows 10 yrs. from now we might all be towing to the sound of a turbo singing on a new MC:). I love that sound!! Keep up the good work.

kiteklan
02-14-2010, 02:43 PM
today we had the opportunity to test our boat in a calm day.The boat made 45mph top speed and managed to tow 2 wake-boards at a time. Cruise speed is about 38mph.
I will post some videos tomorrow.

hkallestad
02-14-2010, 06:04 PM
I was just looking at your videos, are you running without a muffler on the exhaust?

FrankSchwab
02-15-2010, 12:54 AM
today we had the opportunity to test our boat in a calm day.The boat made 45mph top speed and managed to tow 2 wake-boards at a time. Cruise speed is about 38mph.
I will post some videos tomorrow.

Man, that's a great picture to see.

Congratulations on a marvelous build. You are my hero.

/frank

thatsmrmastercraft
02-15-2010, 02:59 AM
Sounds like you hit a home run with that prop. 45 mph for a top speed is right on. How many RPM was that? I assume you had plenty of power to get those two wakeboarders out of the water.

kiteklan
02-15-2010, 05:29 AM
http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54631&stc=1&d=1263149068I was just looking at your videos, are you running without a muffler on the exhaust?

There is a water cooled egzhost,engine is cooled by fresh water closed system and the fresh water is cooled by salt water and salt water discharges with the egzhost gas mixed after cooling the turbo.Why did you ask?I think you like the sound :)

kiteklan
02-15-2010, 05:49 AM
here is the trailers last version 2 ,works fine.May give inspiration who would like to make a trailer. Last photo is from the waterproof stop/tail/signal light worked fine.

TRAILER v1 BEFORE WITH 2 axels ,disadvantage hard to move around ,hard to hook,more tires /axels more maintanence.
http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54077&stc=1&d=1262042494

kiteklan
02-15-2010, 06:05 AM
Sounds like you hit a home run with that prop. 45 mph for a top speed is right on. How many RPM was that? I assume you had plenty of power to get those two wakeboarders out of the water.

The RPM is about 4000-3800 (max of engine is 4200) and the prop is just fine and saying for the records one more time ," I would love to have a 1:1.25 or 1:1.5 gearbox instead of 1:2"
the 1:2 gearbox is working good but I beleive I have more power on the engine which I cant take out as speed.

On the other hand with 1:2 gearbox and with this high pitch prop ,We had full load of people about 6 man on the boat and still managed to make to 42mph top speed and able to tow/take up 2 wakeboarders with 4 people on board,towed them with constant speed.

thatsmrmastercraft
02-15-2010, 10:22 AM
The RPM is about 4000-3800 (max of engine is 4200) and the prop is just fine and saying for the records one more time ," I would love to have a 1:1.25 or 1:1.5 gearbox instead of 1:2"
the 1:2 gearbox is working good but I beleive I have more power on the engine which I cant take out as speed.

On the other hand with 1:2 gearbox and with this high pitch prop ,We had full load of people about 6 man on the boat and still managed to make to 42mph top speed and able to tow/take up 2 wakeboarders with 4 people on board,towed them with constant speed.

Given the availability of the engine/transmission, you sure seemed to make the most of the available performance without near as much trial and error as one would have suspected. Top speed and max RPM are about as close to being right on as could be. Great job!

hkallestad
02-15-2010, 04:34 PM
http://www.mastercraft.com/teamtalk/attachment.php?attachmentid=54631&stc=1&d=1263149068

There is a water cooled egzhost,engine is cooled by fresh water closed system and the fresh water is cooled by salt water and salt water discharges with the egzhost gas mixed after cooling the turbo.Why did you ask?I think you like the sound :)

It sounds great, I was just wondering;-) Are the newest videos coming?

kiteklan
02-16-2010, 12:37 AM
Hey my friends are newbie wakeboarder so do not expect much:)

http://www.youtube.com/watch?v=icAYaJSrS38

kiteklan
02-16-2010, 12:38 AM
2nd Latest Video ,wakeboarder behind the diesel MC

http://www.youtube.com/watch?v=hTLfLnsUTL4

cbryan70
02-16-2010, 01:39 AM
Looks good, next time your out and you have the time do a from idle to full throttle shot of the wake, curious to see how it would be pulling up a skier.

kiteklan
02-16-2010, 09:16 AM
http://www.kiteklan.org/video/wakeboard-1

hkallestad
02-16-2010, 09:41 AM
Great! All you need now is ballast bags and to trim the rope to the correct lenght so you can get som air;-)

kiteklan
02-16-2010, 09:58 AM
Great! All you need now is ballast bags and to trim the rope to the correct lenght so you can get som air;-)

how many kg we need to load?instead of ballast bag ,I have heavy friends:) will it work.

hkallestad
02-16-2010, 10:56 AM
I don't know on your model, but i put about 400 kg in my 89 prostar+ maybe 3 persons in the boat(only in calm water), 200 kg sack in the rear(sofa is out), 80 on each side and a little bit in the front(all 3 persons in the front seats). Your prostar seem to be higher(higher freeboard) than mine, so it should handle some ballast fine, but be careful, you seem to get some rough water in your ocean spot. The prostar makes a very small wake without ballast, it will not get great with ballast but it will help quite a bit, the faster you go the flatter the wake gets, I go about 20 miles for the best wake/speed combo with mine, if I go faster the wake get really small.

kiteklan
02-16-2010, 11:08 AM
I don't know on your model, but i put about 400 kg in my 89 prostar+ maybe 3 persons in the boat(only in calm water), 200 kg sack in the rear(sofa is out), 80 on each side and a little bit in the front(all 3 persons in the front seats). Your prostar seem to be higher(higher freeboard) than mine, so it should handle some ballast fine, but be careful, you seem to get some rough water in your ocean spot. The prostar makes a very small wake without ballast, it will not get great with ballast but it will help quite a bit, the faster you go the flatter the wake gets, I go about 20 miles for the best wake/speed combo with mine, if I go faster the wake get really small.

Thanks, great information.

pkreusch
02-17-2010, 10:08 AM
Great job on boat and trailer!!! Read your thread start to finish and I'm impressed. Outstanding.

kiteklan
02-18-2010, 04:02 AM
Great job on boat and trailer!!! Read your thread start to finish and I'm impressed. Outstanding.

Thanks a lot,I am also very satisfied from the result.

kiteklan
02-18-2010, 08:09 AM
Kiteklan Mastercraft Propeller Underwater action video (http://www.youtube.com/watch?v=5f7x26hHJRg)

Special Video you will like it :D
Can only see this without being choped down :D

thatsmrmastercraft
02-18-2010, 10:03 AM
That is a cool video.

hkallestad
02-18-2010, 10:36 AM
Cool! Gopro hero HD camera? I have one too, really cool camera;-)

C36
02-18-2010, 06:54 PM
hkallestad/kiteklan:

In terms of wakeboarding performance, there is quite a bit of difference between 1987-1990 ProStar 190 hull and 1995-1997 ProStar 190 hull, to my understanding.

Although the 1987-1990 hull was also designed as a three-event hull it has a decent (but not outstanding when compared to some of the other ProStar hulls) wake for wakeboarding at lower speeds. For more detail on the 1987-1990 hull click here (http://www.mastercraft.com/teamtalk/showpost.php?p=587688&postcount=8).

Waterski Magazine rated the 1995-1997 hull well for barefoot, wakeboard, trick, and kneeboard in their 1996 Boat Buyer’s Guide. The 1995-1997 ProStar 190 hull proved to be so versatile it remained in production for eight consecutive years (1995-2002) under five separate model names – ProStar 190, 19 Skier, SportStar 19, ProStar 195, and X-5. In 1996, MasterCraft changed the ProStar 205 to mirror the changes made to the ProStar 190 in 1995. Note the ProStar 205V went on to become the original X-Star/X-2/X-1 with legendary wakeboard performance. For more detail on the 1995-1997 hull click here (http://www.mastercraft.com/teamtalk/showpost.php?p=587690&postcount=10).

As for weighting, the attached article may be helpful. Note this article also makes reference to the "mid-1990" ProStar as having an "excellent" wake when weighted (see picture of 1995 ProStar 190 in the bottom right corner).

And to answer your other question, people = ballast (and they can be easier to move around too). :)


I don't know on your model, but i put about 400 kg in my 89 prostar+ maybe 3 persons in the boat(only in calm water), 200 kg sack in the rear(sofa is out), 80 on each side and a little bit in the front(all 3 persons in the front seats). Your prostar seem to be higher(higher freeboard) than mine, so it should handle some ballast fine, but be careful, you seem to get some rough water in your ocean spot. The prostar makes a very small wake without ballast, it will not get great with ballast but it will help quite a bit, the faster you go the flatter the wake gets, I go about 20 miles for the best wake/speed combo with mine, if I go faster the wake get really small.

kiteklan
02-19-2010, 04:41 AM
Thanks for the information .What I had noticed is the boat makes a very nice wake upto 20mph ,after that it gets flatter at the behind on a 15 meter distance.We are very new on this wakeboarding ,you know i am a kiteboarder and the wakes we have are always natural.
Now here is my question ,how short can the rope be without creating a safety hazard?

hkallestad
02-19-2010, 05:45 AM
Down to 1 meter;-) As long as you don't hit the boat itself when you fall it doesn't matter I would say, you can't get into the propeller, it's under the boat you know. Experiment with ballast/speed and find the best possible wake(takes time) and adjust the rope lenght so you hit the wake where it gives you the best pop(in front of where the wake breaks). Also a proper wakeboard with boot bindings will help, kiteboards are flatter and longer and not ideal for jumping behind boats.

C36
02-19-2010, 03:29 PM
Thanks for the information .What I had noticed is the boat makes a very nice wake upto 20mph ,after that it gets flatter at the behind on a 15 meter distance.We are very new on this wakeboarding ,you know i am a kiteboarder and the wakes we have are always natural.
Now here is my question ,how short can the rope be without creating a safety hazard?

kitelan:

Most people tend to use a shorter rope (~55' or ~17 m) and slower speeds ~18 mph when learning (softer falls).

small child learning = 12-16 mph
child/small adult learning = 16-18 mph
adult learning = 18-20 mph
adult advancing = 20-24 mph

Rope length - shorter rope length (~55' or ~17 m) will make it easier to learn to jump wake-to-wake, but I have also heard some suggest that a longer rope (~70' or ~21 m) makes it easer for beginners to commit to their jumps because they will be landing in the flats between the wakes instead of "stacking" or landing on top of the opposite wake. Once you get more comfortable you will likely want to increase the length of the line. Wakesurfing lines will be much shorter that this to get you into the pocket of the wake just off the transom.

Look for a non-stretch wakeboarding line with a floating handle (waterski lines stretch and some tournament waterski handles sink). Most wakeboarding lines come in segments so you can adjust the length as needed.

kiteklan
02-19-2010, 06:53 PM
Thanks a lot C36 for this good information.

kiteklan
03-04-2010, 03:38 PM
Special thanks to C36 for his help.

Today I had completed the decals in my friend Naki's company MTN.


tomorrow we will install a water separator the fuel line and a water particle filter on the water intake.

It is amasing how many details are hidden on a renovation and rebuilt.

Still the boat has a lot to do.

"Yakup" thanks to you also for your excellent craftsman.

thatsmrmastercraft
03-04-2010, 03:42 PM
Looking good. Very impressive job. :cool:

kiteklan
03-06-2010, 04:18 PM
Today we had tested the boat with new water filter and the fuel/water separator.
As usual the first thing to check was if there are any leaks when the boat was in the water then I find out that the impeller of the salt water pump was not functioning and there was no cooling ,luckly the engine saved and we had installed a new impeller worked fine.

We cruised on a calm sea about an hour constant speed 35-40mph and took attention of the coast guard :) they were chasing us with a Zodiac 40hp and could not catch us until we had recogized that were being chased and stoped.they looked at the papers and the licence and asked a lot of information about the boat,I think they like it :)

americanskierJim
03-06-2010, 04:25 PM
Gerat Job the boat looks wonderful. LOL Good for you giving the coast gurd and run for there money. Sound like a fun day on the water.

kiteklan
03-14-2010, 02:28 PM
I took some photos for those who would like to see after the latest addittions.
Sounder with GPS works great,tested the speed with GPS and get a clean 40mph top speed.
and cruise 35mph.Had some vibration on the max speed that is why I will take the prop to the balance shop maybe also the shaft.I still think I need a higher pitch prop since the engine has no load on the max speed.
Sounder works great shows what is underneath up to 20mph which is fine.

Now you may think what I am gonne do with sounder,I had installed it coz we may use this boat also for scuba some time.

Still looking for a good wakeboarder and a barefoot person :) to tow.


by the way check the video.

http://www.youtube.com/watch?v=UiPPKVrUisQ (http://www.youtube.com/watch?v=UiPPKVrUisQ)

kiteklan
03-25-2010, 10:14 AM
I am in USA /Washington D.C..Looking forward to buy some parts for my 1997 MC /mostly interior.
Can anyone give me help to source it around?

JLeuck64
03-25-2010, 10:37 AM
Are you in Washington the state or Washington DC the Capitol? How long are you going to be in the Country? Are you just looking for dealer locations?

kiteklan
03-25-2010, 01:22 PM
sorry I am in D.C. you know some whom I can buy some parts for boat,cupholders ect.

HdGPS190
03-25-2010, 05:04 PM
I don't think you will find anything in DC, but if you cross over into Virginia there is a West Marine in Old Town, Alexandria (about 10 miles from downtown DC) at:
601 S Patrick St
Alexandria, VA 22314-4018
They will have most basic boat supplies you need.

The closest MC dealership is about an hours east (across the Bay Bridge), just beyond Annapolis, Maryland at:
Bay Watersports
108 Hess Frontage Road
Grasonville, MD 21638

There are also several marine supply stores in Annapolis itself, such as:
Fawcett Boat Supplies
919 Bay Ridge Road
Annapolis, MD 21403

Annapolis itself is also a neat place to visit if you have the time and a rental car to head out that way.

kiteklan
03-26-2010, 12:01 PM
I don't think you will find anything in DC, but if you cross over into Virginia there is a West Marine in Old Town, Alexandria (about 10 miles from downtown DC) at:
601 S Patrick St
Alexandria, VA 22314-4018
They will have most basic boat supplies you need.

The closest MC dealership is about an hours east (across the Bay Bridge), just beyond Annapolis, Maryland at:
Bay Watersports
108 Hess Frontage Road
Grasonville, MD 21638

There are also several marine supply stores in Annapolis itself, such as:
Fawcett Boat Supplies
919 Bay Ridge Road
Annapolis, MD 21403

Annapolis itself is also a neat place to visit if you have the time and a rental car to head out that way.
Thanks a lot , I will check those.

Boater_C
03-27-2010, 05:15 AM
Thanks for sharing your MC build! Very interesting! Great job!! :)

kiteklan
04-15-2010, 05:33 PM
hi all,I had installed a new propeller with a 29"Pitch and 15.7" diameter also a side scanner sonar and GPS Combo of humminhbird(798Ci Si).new prop is 1" bigger then the previous.

americanskierJim
09-02-2010, 10:21 PM
Kiteklan, Wow I like your boat looks real nice. I am looking to restore another boat. I was just wondering how hard of install it was to put the motor in? NOt sure if I want to Diesel or put a 454 bigblock on the boat. Thanks AMSJim

jipster43
09-05-2010, 11:25 PM
I have no idea how this thread slipped past me all these months, but WOW!!! What an awesome job! The decals look great too! I'm all for putting a name on your ski boat. All the ski boats had 'em back in the 70's (where I'm from anyway).

JP :)

kiteklan
09-06-2010, 08:23 AM
Kiteklan, Wow I like your boat looks real nice. I am looking to restore another boat. I was just wondering how hard of install it was to put the motor in? NOt sure if I want to Diesel or put a 454 bigblock on the boat. Thanks AMSJim

Jim,It is not really hard ,if you look at the previous pages of this thread you will see 2 engine mount plates (yellow painted).Which we had manufactured on our own.If the engine will not fit on the original mounts just make some wider mounts and place the engine on it,mark the correct position , make the alignment roughly then take out the plates and drill them.you should have some adjustment room on engine mounts(the one with suspension) for final adjustment.
This is how we had done easy job :).If you will put a diesel be sure it is more then 200 HP and light weight engine.With my Steyr 236 HP (4400) Rpm and a 2:1 ZF gear box I had managed to make easy 40-43NM at salt water.I am pretty sure with a ZF 1:1.25 It would easly go near 50NM.In our country diesel is %30 cheaper the gas ,that is why we go diesel.

kiteklan
09-06-2010, 08:26 AM
I have no idea how this thread slipped past me all these months, but WOW!!! What an awesome job! The decals look great too! I'm all for putting a name on your ski boat. All the ski boats had 'em back in the 70's (where I'm from anyway).

JP :)

Thanks ,It has a huge prop with a high pitch that is why we name the constant pull "Rhino".Also we have to name to boats in Turkey it is the law.

kiteklan
09-06-2010, 08:45 AM
I am very satified from my diesel engine,fuel economy and over all performance .100lt goes for me more then 2 weekends without caring the how far the throttle goes ,other then 1 minor fuel filter incident which took me only one hour to fix I did not have any problems.
Boat is reliable on the sea up to 15knot of wind and 1 meter waves.
I wish I would have one of the sea type mastercrafts to renovate.

d2jp
11-10-2011, 08:37 AM
Searching for threads on Prostar renovation last night, I found this thread. Very interesting to see how much work and engineering was put into this boat.

Any further word from Kiteklan?

kiteklan
11-11-2011, 05:07 AM
d2jp \all the work actually less then 2 months.
still using the boat did not have anything other then the usual maintanence.I am very satisfied from the fuel economy and the speed upto 40-43knots ,the only thing I can say is meditrenean sea is to rough for a prostar after 8knot of wind but still usable upto 14knots\after that park to a bay :) waves make you to much disturb on ride /

kiteklan
11-11-2011, 05:14 AM
Searching for threads on Prostar renovation last night, I found this thread. Very interesting to see how much work and engineering was put into this boat.

Any further word from Kiteklan?

my reply is below

kiteklan
11-11-2011, 05:16 AM
Does anyone saw a similar `dizelination` project,I was not checking the forum in the recent months.

thatsmrmastercraft
11-11-2011, 10:24 AM
Really great to hear the project worked out for you so well. It was an extremely interesting thread to follow. I have not seen another diesel-powered conversion on here since.

mikeg205
11-11-2011, 10:47 AM
yeah - wish I joined TT when it was going on... but great to read the thread and see a different enigne get installed....

stars83stripes
11-11-2011, 03:19 PM
Great thread. I would love to see someone tackle a project like this in the states! Diesel power!

kiteklan
11-12-2011, 05:48 AM
If i would be in states definetely i would get into this as business.there is so many boats in states which the hull is great but engines are bad

kiteklan
04-27-2012, 07:05 AM
Diesel Conversion,after using the boat so long time,I ca say that I did not have any problems mechanically but,the meditrenean see is so rough for a prostar,if the wind is over 7knot the waves make the voyages a little tiring.Fuel Economy is great,you can fill the tank and forget for a couple of weekends.My transmission ratio was 2:1 only thing I complain is this issue since mastercraft need more rev. other then the torque.I wish a professional skier or wakeboarder try it give their opinion.

Double D
04-27-2012, 09:21 AM
Diesel Conversion,after using the boat so long time,I ca say that I did not have any problems mechanically but,the meditrenean see is so rough for a prostar,if the wind is over 7knot the waves make the voyages a little tiring.Fuel Economy is great,you can fill the tank and forget for a couple of weekends.My transmission ratio was 2:1 only thing I complain is this issue since mastercraft need more rev. other then the torque.I wish a professional skier or wakeboarder try it give their opinion.

Yeah, these flat bottom boats are not made for big sea's. I live close to Lake Erie near Cleveland, Ohio and will not take my boat up there.... Inland lakes only for me...

thatsmrmastercraft
04-27-2012, 09:52 AM
Great to hear that all your efforts have paid off so well.

kiteklan
04-27-2012, 10:11 AM
Engine is 4200 @rpm and it needs 1.15 or 1.25 max 1.5 to 1
2:1 is not t'he right gearbox,the prop is very high pitch with high diameter efficiently made 42.5 knots ,i am hoping to change t'he gearbox and reach 50 knots

thatsmrmastercraft
04-27-2012, 10:19 AM
That would be 57 mph. I'm not the hull expert here, but you might find it difficult to reach that speed.

cbryan70
04-27-2012, 10:41 AM
If he does reach that speed the front end would be pushed so far down it would be scary to drive. 03 has had his boat up to speeds of that level and says controlling it is scary.

kiteklan
04-28-2012, 02:32 PM
I had a really stable run with 42knots even it was not flat like a lake.
If you will look at the previous threads you will see the size of the propeller,and the pitch,It is really huge.Once You get on the speed you are on a very steady motion and very stable.
I will post a video later from the max throtle run.you will like it :)

kiteklan
04-28-2012, 02:35 PM
http://www.mastercraft.com/teamtalk/showpost.php?p=672653&postcount=223

The propeller :D

http://www.mastercraft.com/teamtalk/showpost.php?p=654174&postcount=166

kiteklan
04-28-2012, 02:41 PM
test video http://www.youtube.com/watch?v=e-udiUiizqo

46Chief
09-09-2012, 02:40 PM
I love this mod, wish there were more like it that were easier to find on the net. Please give us an update on how well it ran for you this summer.

MC209
09-09-2012, 03:54 PM
wow wow wow. alls I can say! great project awesome progress. way to stick with it for so long! seeing the end result sure is purdy!

CC2MC
09-09-2012, 04:15 PM
Great job! I am digging the deisel engine. That is a ton of work that you had to put into it and job well done. I think the boat sounds like a fishing trawler at low rpms! Thought about opening up a charter business?

When I used to work for Chris Craft boats, we shipped out a ton of diesel boats over to Europe. I had the opportunity to drive a couple and it takes some getting used to, as compared with the gas. That was a great find. BTW, how did you come upon this boat? Was it a flood damaged boat or stolen or what?

kiteklan
09-10-2012, 07:04 AM
:) Still bigsmile after 2,5 years, posting 2 videos for you from this weekend.In Silifke River.
Strapless Skimboard.

Mastercraft on the GOKSU River by Kiteklan (http://youtu.be/hPSsLi4Rg7E)

I am aware of the small black pufffs that is because of the bad quality diesel and timing adjustment.:cool:

For 1/2 Throttle RUN Check the next Thread!!!!

kiteklan
09-10-2012, 07:12 AM
1/2 Throttle Run (http://youtu.be/hPSsLi4Rg7E)

Video Talks