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2005 XStar restoration, story so far

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  • 2005 XStar restoration, story so far

    We're about to fit the new engine to our Xstar project, here are some photos from the project... (we're now in the middle of reconnecting / re-fitting the ancillaries, next phase, re-fitting the engine back into the boat)
    Attached Files
    Last edited by lazyade; 12-22-2012, 05:18 PM.
    '92 190 Prostar 260hp Indmar.

  • #2
    Too bad on the first motor - it gave up its ghost way too soon.... great chronicle...keep the pics and updates coming.
    sigpic...A bad day water skiing still beats a good day at work...1995 Pro Star 205....

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    • #3
      Originally posted by mikeg205 View Post
      Too bad on the first motor - it gave up its ghost way too soon.... great chronicle...keep the pics and updates coming.
      We're thinking about having the original engine rebuilt, the bores were not scored, just need cleaning up. We'll probably get the cam and crankshaft checked and then with a new set of pistons and shells it'll hopefully be good for someone else. Oh and the heads needs some work too, will get them shot blasted first and see what they come up like.
      '92 190 Prostar 260hp Indmar.

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      • #4
        Then a new trailer? That thing was definitely not designed for the star.

        Even if the cylinder walls weren't scored I'd consider boring them out, the extra power in that hull would be nice

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        • #5
          I'm in the UK and we have different regulations on trailers, they have to have brakes above 750 kg and also a double axle for even heavier loads.
          '92 190 Prostar 260hp Indmar.

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          • #6
            Originally posted by lazyade View Post
            I'm in the UK and we have different regulations on trailers, they have to have brakes above 750 kg and also a double axle for even heavier loads.
            It just looks tiny under that boat! And since I'm posting in your thread I will take the time to say its been fun to follow and nice work!

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            • #7
              Nice project boat, and love the G4 Rangie.

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              • #8
                What happened to the original engine? Acquired that way? Or, any lessons learned you might want to share, if not tooo painfull....

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                • #9
                  Originally posted by mcparadise View Post
                  What happened to the original engine? Acquired that way? Or, any lessons learned you might want to share, if not tooo painfull....
                  Here's more:
                  http://www.mastercraft.com/teamtalk/...ad.php?t=50535

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                  • #10
                    We got the engine back in yesterday. We had a real problem with getting the engine mounting's aligned (turns out the guy who shot blasted them had put the stern mounting back together incorrectly - the rubber was under the engine mounting! Plus the stern mounting are handed - we had them on the wrong sides). But after a few hours of cursing and persevering it's, located and bolted down.

                    Next job (today) is to reconnect the wiring loom and start her up. Then engine alignment, that's going to be fun (we haven't yet put the prop shaft through so I don't think perfect engine alignment matters too much yet).

                    Here are some photos of yesterday's exploits (note the incorrectly fitted stern engine mountings)...
                    Attached Files
                    '92 190 Prostar 260hp Indmar.

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                    • #11
                      Hello Adrian

                      Wow your project is moving on well ,
                      looks like you are going to be on the water before me.
                      1 observation , does your model not have a through the hull engine oil drain kit?

                      Kevin

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                      • #12
                        Originally posted by Worthing skier View Post
                        Hello Adrian

                        Wow your project is moving on well ,
                        looks like you are going to be on the water before me.
                        1 observation , does your model not have a through the hull engine oil drain kit?

                        Kevin
                        good observation on the missing oil drain hose

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                        • #13
                          Originally posted by lazyade View Post
                          I'm in the UK and we have different regulations on trailers, they have to have brakes above 750 kg and also a double axle for even heavier loads.
                          Nice job as for the trailer, I'd install new bunks so they extend past the transom, all that weight needs to be spread out and put some guide poles/posts on, wouldn't want the boat getting sideways on the trailer, not good for props.

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                          • #14
                            We're looking to get some new guide poles.

                            On the drain hose, we couldn't be bothered to fit the old one, we'll just drain it through the dipstick tube with a vacuum oil changer.
                            '92 190 Prostar 260hp Indmar.

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                            • #15
                              Further update....

                              Engine is now back in and running fine. We had real problems trying to find the correct intake manifold gasket, see my post here http://www.mastercraft.com/teamtalk/...ad.php?t=52328

                              But once we got the right gasket it sealed fine - and now no water loss (we had to change the oil a few times to get the water out of it). We've also stripped out the rudder seal and fitted a new one and also a new prop seal (have gone for the new style Mastercraft one that is water fed).

                              Just waiting for a not too cold day, with flat oceans, to take her our for a shakedown and running in of the new engine. Still got some work to do in polishing everything up, cleaning the hull (which has barnacles on it still from the previous owner), and some work on the stereo. But fingers crossed she'll be in working order for late spring / summer - whenever it finally arrives here in England.
                              '92 190 Prostar 260hp Indmar.

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