Go Back   TeamTalk > Maintenance Tips, How-tos and Refurbishing Topics > Towers

Reply
 
Thread Tools Display Modes
  #1  
Old 07-07-2013, 11:56 PM
willg willg is offline
TT Enthusiast
 
Join Date: May 2013
Boat: 02 X-Star
Location: Northeast
Posts: 116
Replacement Tower Pad DIY/ How to /fix shaky tower

Ok, so after calling dealers for weeks, I decided to make my own set of tower pads. Unfortunately, I don't have pictures, but the procedure is straightforward. I have a 2002 MC X-Star w/ zero flex flyer tower. My tower shook badly enough to hit the windshield when I went over waves.

1) Order the rubber. I used this Ultra-Strength Neoprene Rubber, Plain Back, 1/8" Thick, 4" Width, 36" L, 70A Durometer. This is much thicker than the factory pads, but worked perfectly. Had plenty for at least 8 individual pads.

2) Buy a hot knife. I used this one Harbor Freight Hot Knife, and bought this knife for the blades Harbor Freight Hobby Knife

3) Remove the tower. I removed the top section of my tower first, then the legs. For the legs you need a 1/2" allen wrench (or socket) and a 19/32" socket. Also I needed an 19/32" wrench to get to the rear tower nuts (if you don't have these tools, Harbor Freight has them for a good price). Some anti-seize compound on the ends of the bolts before removing the nuts eases the process. I had to cut the wires for my tower light, but was able to use crimp connectors to reattach it.

4) Make a template. On the front of the legs, I only made a template for the hole in the bottom of the tower (where the light wire ran through) and the bolt hole. The backs just have a bolt hole. Once I made this out of paper, I cut those two holes into a ~2"x4" piece of rubber. This allowed me to remount the tower.

5) Remount the tower w/ rough pads under legs. Tighten the bolts to ~75% of the final torque. For me, this was when the rubber began to squish out from under the leg.

6) Trace the leg for the tower on the pad. I used a silver sharpie.

7) Remove tower & pads.

8) Cut out pad with hot knife. I still had some nicks and rough spots around where I cut, so I actually sanded the edge of the pad with 120 grit sandpaper. This evened it out.

9) Reinstall the tower. I cleaned the threads of the hex bolts and liberally applied anti-seize. I torqued the bolts on mine enough so that the rubber squished out maybe 1/16" out around the leg. Just tight enough that when I turned the hex bolt without a wrench on the nut, it was stiff. It's hard to say what torque to tighten to, because the threads were wet.

10) My boat was missing the appropriate plastic washers that fit in the hinge of the tower (where the top section attaches to the leg in the front). I used neopreme washers from Home Depot, two on each side. These exact ones.

The tower used to rattle and shake quite badly. Now it is MUCH stiffer. I can barely shake it with my hands. Overall, this was a huge improvement and well worth the time and effort. All in, it cost me about $38 (I had the tools). I was so impressed with the results I had to post this up
Reply With Quote
  #2  
Old 07-08-2013, 12:12 AM
mikeg205's Avatar
mikeg205 mikeg205 is offline
Moderator
 
Join Date: Aug 2011
Boat: 1995 Pro Star 205 5.7 Liter
Location: Plainfield - Joliet, IL
Posts: 10,400
Send a message via Skype™ to mikeg205
Show us some picss...use photobucket.com.
__________________
...A bad day water skiing still beats a good day at work...1995 Pro Star 205....
Reply With Quote
  #3  
Old 07-08-2013, 12:24 AM
willg willg is offline
TT Enthusiast
 
Join Date: May 2013
Boat: 02 X-Star
Location: Northeast
Posts: 116
Quote:
Originally Posted by mikeg205 View Post
Show us some picss...use photobucket.com.
Im not with the boat right now, but can try to get some next weekend.
Reply With Quote
  #4  
Old 07-08-2013, 12:26 AM
mikeg205's Avatar
mikeg205 mikeg205 is offline
Moderator
 
Join Date: Aug 2011
Boat: 1995 Pro Star 205 5.7 Liter
Location: Plainfield - Joliet, IL
Posts: 10,400
Send a message via Skype™ to mikeg205
that would be great
__________________
...A bad day water skiing still beats a good day at work...1995 Pro Star 205....
Reply With Quote
  #5  
Old 07-08-2013, 01:09 AM
Mark rsa2au's Avatar
Mark rsa2au Mark rsa2au is offline
TT Enthusiast
 
Join Date: Mar 2013
Boat: Mastercraft X5 2001. 310hp preditor
Location: Australia
Posts: 182
yes please - pics!

Nice write up!
Reply With Quote
Reply

Thread Tools
Display Modes

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off


All times are GMT -4. The time now is 11:22 AM.