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View Full Version : 93 ProStar 190 S&S aka "Garage Queen" Ongoing Refurbishment


Waterskibum
06-09-2014, 03:45 PM
It has been almost eight years that my PS190 has lived here in Florida, and she has been the center point of many fun times, and lots of great memories; but she is showing her age being that she is 21 . Figure it is time for another refurbishment/restoration.
In 2006-2007 we gave her and the trailer a heavy cosmetic refurb, with the trailer receiving the most love. Trailer got a new torsion flex axle, electric brakes, updated wheels and tires, sandblasted and powdercoated, new carpet on the bunks, all new wiring, and LED lights. Fenders got wet sanded and polished.
Before and after on the trailer:
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202007/DSC00009.jpg
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202007/P1010007.jpg
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202007/TrailerGarage.jpg
She got some repairs done, and a lot of cosmetic enhancements. All the underwater gear and anything that could be pulled from the motor were chromed. Motor and trans were sanded and repainted. Bilge cleaned. MCX exhaust manifolds and 3” straight exhaust with stainless tips installed. Some wiring work, and general maintenance.
Motor before and after:
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202007/DSC00010.jpg
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202007/P1010012.jpg
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202007/P1010011.jpg
Since then she has lived a life of luxury, either on the boat lift, or on the trailer. Waxed and pampered, and not used as much as I would have liked. She became the neighborhood “trailer queen”.
Fast forward to late 2008-2009 when I met my wife to be, and step-daughter to be. Bought a house, spent way too much time on the house, and her in the garage.
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202014-2015/Garage.jpg
Fast forward to 2013. Moved into the new (to us) house right after Memorial Weekend. Spent way too much of the Summer on the house, and her in the garage.
http://i248.photobucket.com/albums/gg196/waterskibumfl/Swans%20Landing%202013/SSPBandJasmineback.jpg
I became more active on TT in 2013 which activated my MCOCD, thanks Kyle, Double D, Rat, DooSPX, and everyone else. Now that the new house and landscaping are done, we can ski as much as possible too.
The project list below is what is planned for 2014-2015, and probably more to come. My wife saw the list and asked how much this was going to cost. I told her “a helluva lot less than a new boat!”
2014- 2015 Prostar Refurbishment Time frame

Fix gauge panel mount points June-14 Done
Replace switch panels June-14 Done
Install Stargazer June-14 Done
Replace clock June-14
Replace ignition switch July-14
New winch and jack July-14
Redo the MC Decals on winshield,
Safe T Top and Gas tank cover July-14
Redo the Indmar decals on
both sides July-14
Remove winshield and powdercoat
the frame. Replace rubber seals. October-14
Replace piping and have
interior fixed October-14
Replace doghouse cupholder October-14
Have pylon chromed or polished October-14
Install OJ Dripless Shaft Seal October-14
Install underwater lights October-14
Replace carpet November-14
Replace gauge and switch panels November-14
Restore steering wheel November-14
Get fuel gauge working November-14
Install LED interior lights and
cupholders November-14
New speakers, amp and sub
(JL Audio) December-14
Stainless steel rub rail installed January-15
Gelcoat repairs- keel area January-15
Redo gelcoat on fenders to match
the boat and trailer January-15
Install skid pads on trailer fenders January-15


Stay tuned for the beginning and hopefully the end of the journey :)
Dave

cbryan70
06-09-2014, 04:05 PM
I just took the clock out of my 93 if you are looking for one. Not sure what they go for.

Double D
06-09-2014, 04:15 PM
My wife saw the list and asked how much this was going to cost. I told her “a helluva lot less than a new boat!”


Best line ever!!!! Keep us posted!!

mgs96ps
06-09-2014, 04:31 PM
Any chance you could write a little review on those exhaust manifolds?

Waterskibum
06-10-2014, 01:10 PM
I just took the clock out of my 93 if you are looking for one. Not sure what they go for.
Thanks for the offer. Think I might have found a brand new one. Will let you know if the deal falls through.

Best line ever!!!! Keep us posted!!

LOL! Knew you would like that line :D

Any chance you could write a little review on those exhaust manifolds?

Can't find the old thread. I would not say there are any "cons" to the MCX manifolds. To install them I did have to reverse the LT-1 cylinder head cooling lines as the outlets on the manifolds were on the rear, where the stock Indmar ones were on the front. No biggie though, just remove the plugs from the back of the heads, pop the lines off, and swap sides. Pros- MCX manifolds are about half the weight of the stock ones. Got to move up to 3" exhaust, straight through (no mufflers), and S/S tips. Sounds much better, and throttle response was better.
One other Con would be price. They are really expensive new. I got a killer deal on them back in 06. Personally I would not have done it if I had to buy them new. Just not enough performance increase to justify the $$.

mgs96ps
06-10-2014, 01:16 PM
Maybe just a short list of pros and cons on review.

cbryan70
06-10-2014, 02:52 PM
Thanks for the offer. Think I might have found a brand new one. Will let you know if the deal falls through.

Sounds good. Let me know and ill try to take some pictures of it. It is in great condition.

Waterskibum
06-11-2014, 11:58 AM
As previously mentioned, I have not been skiing as much as I would have liked to. Well, our new neighborhood in on the lake, there are quite a few skiers in there, and we have a slalom course right off our dock area. I have not really skied in the course for about ten years, and I figure 2014 is prime time to start again. I sent Bruce at AWS an e-mail and got a PP Stargazer system ordered before Memorial Day. Installing the PP is really what kicked off the June phase of the project, and got me to fix some other issues that I have ignored for a while.
Started by replacing the switch panels with the ones Kyle made me. I used #8 stainless steel socket cap screws with nylock nuts for the audio control panel. The two switches are for the future LED interior lights, and the underwater lights.
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202014-2015/June14radiopanel-1.jpg
The main switch panel was fun, NOT. Started by drawing out the back of the switches and noting where each different wire went on the switch, bundled each set up wires up, labeled them, then moved the switch one by one, As I took more of them out I realized that they were the only thing holding the panel together. Got them all moved, checked that everything worked, and went to bolt it in. Thankfully the factory nut-zerts were still there, and #8 socket cap screws work there too. I start bolting it in, and realize that the holes in the panel and my mount points are way off. No fault of Kyle’s at all. My boat of course has to be different! There was no way I could reuse the old panel, so I had to destroy Kyle’s hard work to use it.
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202014-2015/June14switchpanel-1.jpg
This is only temporary though, when Kyle gets the gauge panels done I am going to have him do a complete new set for me, and yes, I will provide measurements this time!

Waterskibum
06-11-2014, 11:59 AM
The gauge panel mounts are notoriously weak in this era ProStar, and mine is no exception. Bailing wire and duct tape were my friends for the longest time. What I decided to do was use some 5/16 stainless socket cap screws to match the switch panels, and I epoxied the nuts to the washers, and then epoxied them where the factory nut-zerts were. This worked well; but I’ll probably add some fiberglass mat to strengthen the areas this Winter, and fix the top three mounting points in the dash too.
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202014-2015/June14gaugepanelfix.jpg
Thanks to Jersey Dave for snapping a high-res pic of the steering wheel decal as I was able to have Cheri at Planet H2O make a new one. Not like the factory bubble one; but it works. I have a few extras in black if anyone needs one. Just let me know.
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202014-2015/June14steeringwheelcap.jpg
Next on the list was the PP installation. Servo went easily as did the control unit.
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202014-2015/June14stargazerservo.jpg
http://s25.postimg.org/x78qsrdcv/June_14_stargazer_servo_2.jpg
Fishing the servo power wire through the floor to the motor, well, that is another story. Finally gave up being a contortionist, and decided the floor around the pylon has to come up. To get the floor up requires the seat to be removed. Ok no biggie, except I need a 90 degree Phillips head to get the back two screws out. Ended up using a Ľ inch socket with a #2 Phillips head from the Dewalt. Got those out and moved to the front screws, only to realize that one is completely stripped out. Wanting to reuse the insert in the floor, I decided to try and drill a hole on the stripped screw, and then epoxy another one in there, to try and remove it. Well, that did not work, so had to drill the head off, and use a new mount point.
http://s25.postimg.org/fxs9u5nj3/June_14_seat_rail_epoxy_screw.jpg
http://s25.postimg.org/axutm7hwf/June_14_seat_rail_drilled_out_1.jpg
I was not paying attention, and was frustrated by this point, and did not notice that the Dewalt was eating my seat cushion. Note to self, move the darn seat cushion next time!
http://s25.postimg.org/k4d49hn4v/June_14_seat_cushion_1.jpg
So the seat is out, and I am able to move the floor up enough to fish the wire out and hook up to the servo. As usual, I was not paying attention to the other side of the motor, and must have put too much pressure on the raw water line, and broke my Perko (which had already been repaired previously). Oh well, more epoxy…….
http://s25.postimg.org/ltm7hk2u7/June_14_broken_perko.jpg
Got everything put back together late on Friday night, and went out first thing on Saturday am to test it out. After getting our slalom course mapped in PP, we then went to testing timing through the course to calibrate it. Well the PP would beep at the set speed; but not hold the speed. Back to the dock, and hours of troubleshooting later, I am told that I need a throttle brake because my throttle defaults to idle unless you have pressure on it. Sure would have been nice for PP to mention this in their documentation. Of course I should have known this too. Throttle brake will be here today; but rain will be too, so no skiing tonight. More updates later on.

Jerseydave
06-11-2014, 09:15 PM
Looking good! Man, I want that boat! If I hit the lottery, I'm coming down with a thick stack of greenbacks! In the meanwhile, I hope to someday meet up with you for a pull. (If you ever want to see the liberty bell and climb the steps of the art museum like Rocky I'd gladly give you a pull too!)

east tx skier
06-11-2014, 09:45 PM
Great looking boat! Glad she is getting some well deserved attention. Mine is turning into a garage queen, too. Did my best to rectify that last weekend, however.

Waterskibum
06-12-2014, 12:10 PM
Looking good! Man, I want that boat! If I hit the lottery, I'm coming down with a thick stack of greenbacks! In the meanwhile, I hope to someday meet up with you for a pull. (If you ever want to see the liberty bell and climb the steps of the art museum like Rocky I'd gladly give you a pull too!)

Hehe! Ya money does talk; but make sure it's a thick stack :) You know you are welcome for a visit anytime, and if I am up that way I'll give you a shout.

Great looking boat! Glad she is getting some well deserved attention. Mine is turning into a garage queen, too. Did my best to rectify that last weekend, however.

Thanks Eastie. Ya my friends have been in shock with mine being on the water the last three weekends too. With the PP finally sorted out it is time to get back in the slalom course tomorrow night.

2RLAKE
06-22-2014, 10:20 AM
I really wish I had my 93 up here in Cincinnati right now so I had more time to work on it ... Love what you've done ... Giving me some ideas

One big item I'm missing is the fuel tank cover ... So when I remove my back seat all I see is the fuel tank ... That nice carpeted piece is missing! What is the backer board for that? Also, how is it attached? I'm going to make a new one but would like to know how think the existing one is please

Beautiful boat!

Waterskibum
06-23-2014, 01:53 PM
I really wish I had my 93 up here in Cincinnati right now so I had more time to work on it ... Love what you've done ... Giving me some ideas

One big item I'm missing is the fuel tank cover ... So when I remove my back seat all I see is the fuel tank ... That nice carpeted piece is missing! What is the backer board for that? Also, how is it attached? I'm going to make a new one but would like to know how think the existing one is please

Beautiful boat!

Thanks for the compliments 2RLAKE. She is a labor of love.
Let me shoot some pics tonight. The cover is a thick piece of plastic that is sort of flexible. I'll see if there are any markings on it to ID what it is.
Thought all boats of this era had a cover cause most people pulled their seat when new cause it's pretty useless when skiing anyways.

DooSPX
06-24-2014, 01:45 PM
Looking great Dave. I need to come by and ski sometime soon.

Waterskibum
06-24-2014, 02:34 PM
Looking great Dave. I need to come by and ski sometime soon.

Thanks Jason. Yes you need to get down here sometime this Summer.
PP is in and finally working. Gotta fix my fuel pump this week though.

pnrscott
06-25-2014, 01:26 AM
I have a 94 PS205 with that cover intact. I'll take pics front and back tomorrow.

2RLAKE
06-25-2014, 09:16 AM
I have a 94 PS205 with that cover intact. I'll take pics front and back tomorrow.

great .. thanks

Waterskibum
06-25-2014, 01:14 PM
Ya sorry I did not get pics done. Got busy with family. I'll get some tonight I promise.

pnrscott
06-25-2014, 03:03 PM
2R... here are some pics of fuel tank cover
Plastic thickness is 3/16"
Height is 18 1/4"
top length is 67"
bottom length is 67 3/4"
The plastic covers an arc and the bottom arc is a little longer. When you look down on it vertically, you can see the slight difference.
Since it is covered with carpet, any imperfections in measurement or fit will likely not show.
The clips are across top with loops on bottom to pull for access.
The last photo attempts to show the arc. Note the gap in the center at the bottom.

That's what the original is... Lets see what you create.

mikeg205
06-25-2014, 03:17 PM
2R... here are some pics of fuel tank cover
Plastic thickness is 3/16"
Height is 18 1/4"
top length is 67"
bottom length is 67 3/4"
The plastic covers an arc and the bottom arc is a little longer. When you look down on it vertically, you can see the slight difference.
Since it is covered with carpet, any imperfections in measurement or fit will likely not show.
The clips are across top with loops on bottom to pull for access.
The last photo attempts to show the arc. Note the gap in the center at the bottom.

That's what the original is... Lets see what you create.

wow... thought I was looking at my boat ;)

pnrscott
06-25-2014, 07:21 PM
then you better get busy drying the carpet...

2RLAKE
06-26-2014, 12:06 AM
awesome ... thanks a ton .. i owe ya!

2RLAKE
06-26-2014, 12:07 AM
i'm thinking a cardboard template first ... thanks again

pnrscott
06-26-2014, 01:46 AM
happy to contribute.
my 94 is about as original as they get... I'm the only owner.

DooSPX
06-26-2014, 11:05 AM
Dave, I am leaving to go to WV for July but maybe August make it over your way? I will watching this thread to see the updates on your Bud protour. It is my favorite boat!

Waterskibum
06-27-2014, 01:47 PM
Sorry about the pics. Damn iPhone pictures will not upload to Photobucket. Thanks for getting the pics and measurements pnrscott.

Ya Jason just let me know.

Waterskibum
07-09-2014, 03:02 PM
Latest update- Project Fuel Pump and new Fuel Lines
Unfortunately when dealing with a sometimes temperamental 21 year old, you come across unexpected issues. I was out on the water calibrating the Perfect Pass, and had just finished the 36 mph calibration, when the fuel pump started screeching, and the motor started stumbling. Shut her off, checked the fuel level, and then started her back up. She ran rough all the way back to the dock.
Ok, fuel pump must be not getting fuel. Then I remembered there is a screen on the intake side of the pump that can get clogged and not let the pump lubricate itself, or get fuel to the motor. Well, so much for skiing this day. Off to the garage.
Got the pump off, the screen cleaned, and reinstalled which got me paying attention to the fuel lines from the pump to the motor. I replaced the lines from the tank to the pump in 07; but the lines to the motor had not been replaced to my knowledge, and were possibly original.
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202014-2015/July14origfuellines.jpg
Sent an e-mail to SkiDIM, and they responded that Indmar no longer has them. Now what the heck am I going to do? Thankfully there is a shop in town that specializes is making any and all kinds of lines and hoses. Pulled the originals (sure enough they were date stamped 1994) and took a ride down to Amazon Hose and Rubber. They made them while I waited, and the only thing they did not have was the quick connects which they took off the old lines. I decided to go stainless steel braid for longevity.
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202014-2015/July14fuelintakelines.jpg
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202014-2015/July14fuelreturnlines.jpg
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202014-2015/July14Fuellinesinstalled.jpg
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202014-2015/July14fuelfilter.jpg
http://i248.photobucket.com/albums/gg196/waterskibumfl/ProStar190%202014-2015/July14fuellinesside.jpg
Now I gotta try and get back on my project schedule.

thatsmrmastercraft
07-09-2014, 07:20 PM
The braided stainless looks great!

ncsucarjock88
07-09-2014, 09:33 PM
sweet!

Waterskibum
07-10-2014, 01:41 PM
The braided stainless looks great!

sweet!

Thanks guys! This Winter when the floor is up I am going to do S/S braided from the tank to the pump also. Just feel better knowing the lines are more protected with the braid on the outside. Guess I might as well do AN fittings at the same time verses hose clamps too :)

Anorth09
07-11-2014, 04:15 PM
I Just redid all my fuel lines and did a MSD inline fuel ump on mine. I used an fittings on the fuel rail and added a fuel filer before and after the fuel pump. I would have like to go braided!

Waterskibum
07-16-2014, 02:23 PM
I Just redid all my fuel lines and did a MSD inline fuel ump on mine. I used an fittings on the fuel rail and added a fuel filer before and after the fuel pump. I would have like to go braided!

Would you mind getting some shots of what you did and where you put the pump? Figure my pump is on life support by now, and might do what you did this Winter too.