Just to reiterate, the whole idea of this project was to make a surf boat on the cheap. $150,000 is ridiculous for a good wave, and we are going to try to do this project for less than $10k.

Imperative to this whole project going off is doing things right, and minimizing the half-assedness that creeps into production builds. Starting things off right, she’s going to get a PSS dripless shaft seal setup:

PSS dripless shaft seal

Then it was time to drop the rebuilt 351 back in to get our mind right about alignment. The engine fits like a glove and needed to be in place while the shaft was replaced.

PCM 351 Uniflite

I opted to sack the old strut and rudder in favor of a new rudder from a friend, and the much larger bearing surface of the Malibu strut. I’m pretty pleased how it went together.

dripless Shaft Seal

Just for fun I pitched a chunk of sole in to see the engine’s position. Now you can see just how deep this pig is!

Uniflite Salty Pup

Each of the 1-1/2″ Perko silicon bronze seacocks needed big blocks to fasten to and stiffen the hull. Used some 3/4″ stock and large enough to spread the load of those beasties.

Uniflite seacock

Also we decided to have a larger plank connect to multiple structural members for a rudder bearing. This will make her much more rugged and minimize wear at the packing. Later this will also create a shelf for the mufflers.

Uniflite rudder

Oooo, pretty white bilges:

bilge paint

While out talking with a buddy that custom builds aluminum tanks, I brought up my needs and budget. Turns out Dave happened to have a belly tank and a bow tank that would suit my needs. The decision was made to take a few inches off the bow tank, and split the belly tank in half. He welded everything up, pressure tested, and I brought them home. Then I opted for the 5200/HDPE foot trick. This will isolate the tank from the hull, allow for some vibration damping, and airflow below the tank to preserve the metal.


saddle tanks


bow tank

This will afford a whopping 95 gallons of gas. More than enough for surfing expeditions around the lake. However, don’t tell my wife, but this gives her the legs to get out for deep water halibut and tuna fishing trips if they’re within 40 miles… Let’s keep that a secret, shall we?

In another cost saving measure, we are reusing the mufflers that were in the ski boat. This saves a little cash, and they are reasonably quiet. Also it retains the dual exhaust, and they’re pretty small in the shaft alley, leaving plenty of rigging room.

Uniflite dual exhaust

Of course, if we’re going to stick with the ski boat exhaust, we have to have the shiny bits to go with it, right?

Salty pup=

These will end up with flappers on them for sound deadening and to prevent backflow into the exhaust when we are heavy. Gotta keep that engine happy.

A quick shot of the two seacocks on their pads. Aft will be cooling water for the engine/tranny/stuffing box, forward will be the ballast system inlet/discharge.

Uniflite Perko seacock

Ever had a hard time doing exhaust on a boat? Here is the secret weapon for getting those unwilling hoses onto the metal or fiberglass fittings.

Uniflite KY jelly

Every joint gets double banjos. Also in this image you can see the rudder bearing through the bearing support plate. This was a pain to get lined up, and required shimming because there’s no way to get the exact plane correct in relation to the stuffing box. Ah well, it works.

Uniflite banjo clamp

Salty Pup