2008 X Star ballast upgrade

[XStar08]

Ok so I finally ordered all the components to upgrade the internal ballast of my 2008 X Star.

I would like to post some hints as well as pics as I go trough the process of installing the ballast upgrade. Firstly I wanted to say a big thank you to Spencer from WakeMakers.com who helped me with answering a lot of questions (I guess I sent him over at least 10 e-mails and all of them have been answered very fast and with helpfull information).

I started with having in mind that I'm going to add the Fly High Pro Ballast System which you can buy for example with wakemakers. During the process of nailing down what I really want and need as well as optimizing the components I would need (to get the weight down to reduce shipping costs, to enhance the flow of water in the system, and so on) I realized that the above mentioned system is not exactly what I wanted.

I wanted not to use the T hose barb fittings but the wye fittings to optimize the flow of the water. I also realized that buying the custom made rear bags instead of the standard Fly High rear bags I would spend more money and get less possible weight (720lbs versus 750lbs).

Another thing importent for me was to make sure that by filling only the bags and not the rear tanks water overflowing the bags (vent line) will not be allowed to go backwards to the (empty) tanks but is forced to go out of the boat. I therefore decided to not only use the T assembly stop valves but to go with two check valves on each side of the Y which is bringing together the vent lines of the bag/hard tank.

Beside that I mostly went with what you get also by buying the system. Well, one major issue for me was to reduce the weight of the package which has/had to be shipped as much as possible since it would have to be shipped to Europe. I therefore decided to go green and buy the hose with a local store. By doing this I am also able to get some more hose in case I'm running out of it during installation.

So to get started I placed my order with WakeMakers today. I ordered the following components:
- 2x Fly High Pro X Series Fat Sac
- 2x Fly High Pro X MC X-Star Bow Sac
- 6x Hose Barb Wye Fitting
- 6x Inline Check Valve Fitting
- 8x Flow Rite Elbow Quick Release Connector W746
- 8x Flow Rite Straight Quick Release Connector W741
- 6x Fly High Ballast Bag Plug W731
- 3x Fly High Distribution Flow Mainfold
- 8x Flow Rite Quick Release Connect W743
- 30x Hose Clamps (even if I could get them also from a local store but there was no difference in shipping costs)

To be prepared once the stuff arrives I already bought some 1'' hose, I started with 20 meters which is about 65ft. I also started to build a plattform to have the pumps mounted horizontally instead of vertically (inside the transom) as it is stock. The main goal here is to be able to change the impellers comfortabely. Pictures will follow by tomorrow and I will try to keep you updated regarding the upgrade process.

[spencerwm]

You are very welcome. I am excited to see how it all goes in. Thanks for mentioning Wakemakers and enjoy your star.

[sand2snow22]

Originally Posted by spencerwm

You are very welcome. I am excited to see how it all goes in. Thanks for mentioning Wakemakers and enjoy your star.

Spencer, please call Pat so we can pay and get the parts for our X-Star, too. Our buyer sent wire today! You feeling better?

[XStar08]

So today I had some time to prepare the boat for the install. I removed the rear sundeck as well as all the stuff around the engine to have access to where the pumps should be mounted.

Firstly I planned to mount the pumps above the silent master horizontally. I therefore let build two supports made from aluminum to be mounted at the transom where the pumps are mounted originally. As the transom is not a flat surface and as the mounting points laminated to the transom are not levelled out (it looks as a the guy who laminated was drunk) it would not turn out as I planned. Picture shows the two supports but not the tray where the pumps would be mounted to.

[XStar08]

Instead of building something above the silent master I decided to build it simpel by just putting a tray under the silent master.

Picture shows a wooden template.

[Jerseydave]

Just curious, why are you moving your 3 pumps? Or are you adding more pumps?

I currently have (2) 400# sacs in the rear lockers, but thinking about getting the 720# x-star sacs instead. I tried a 750# sac in there but it's kinda long....hits my heater and won't fill up all the way.
I don't use the rear hard tank at all BTW.

[XStar08]

I decided to put the hose which will fill/drain the KGB on the starboard side and to mount the related 3 way valve (KGB/bow bags) behind the drivers seat. That way I later can add another pump and use this 3 way valve to either fill the bow bags or another bag (kind of a P&P set-up) in case it takes too long filling KGB and the bow bags with one pump. We will see. I therefore let the old hose which fills/drains KGB in there. In case I need a 4th pump I would use that hose to fill/drain KGB as it was before the upgrade.

I'm now waiting for my order to be shipped. Spencer told me they are waiting for some more valves to be shipped to them.

Regarding the location of the pumps I decided to put them under the silent master mounted horizontally. If there is a leak the water can go downwards into the bilge, originally one pump is mounted vertically with the impeller facing upwards so I don't think this problem occurs very often. Well, there is a risk of flooding them but I'll care about that when it's time to do so.

Picture shows the new hose attached to the KGB. It comes from the 3 way valve which will be mounted behind the drivers seat, goes under the cockpit and from there to the KGB.

[CantRepeat]

Originally Posted by XStar08

originally one pump is mounted vertically with the impeller facing upwards so I don't think this problem occurs very often.

You'd be surprised just how often it happens.

[XStar08]

Well, the last 4 seasons (650 hours) nothing happened. We will see, at least now it's better than it was...

[CantRepeat]

Originally Posted by XStar08

Well, the last 4 seasons (650 hours) nothing happened. We will see, at least now it's better than it was...

Well I hope you get another 4 seasons out of it. I'm sure the pump was not run for 650 hours.

My boat had less then a 100 hours on the pump that was mounted upside down went bad. I ended up making amount to turn it over and push it out a bit so the hoses would clear the other pumps.







Keep in mind that if you do flip the pump over you'll need to change the two wires on the switch that provide the power to the relays on that pump. If you don't the pump with work in reverse.