Wake Surf Ballast Project

[brad]

Here are the initial photo's of my Wake Surf ballast project.

Historical background:

- Last year I isolated the internal ballast valves by inserting a switch in the power line.  The on/off switches allow me to continue using the built-in system fill and drain but I can select both tanks or isolate them to port only or starboard only toggling the on/off switches.

- I normally fill 750 lb fly high fat sacks manually in my V-drive lockers; raising the engine hatch and using a tsunami pump with my cigarette lighter.  It's common for passing boaters to come close and ask if I'm okay since they assume something is wrong with the engine with the hatch up.

Current project:

- Decided to install an automatic system to fill the 750 lb fat sacks (one in each V-drive locker;

- Decided to install an additional 500 GPH bilge pump near the engine;

Tasks:

- replaced all the thru hull vents and added an additional one for the rear bilge pump on port side;  added one thru hull vent on each side for fat sacks.  I tried to keep the spacing similar to the original vents plus accounting for reasonable access to them;

- placed a 1 inch thru hull. mushroom style water intake near the engine scoop water intake;  used a 90 degree elbow with female and male ends along with the shut off ball valve;  used a 1 inch threaded to 1 1/8 barb connector for the 1 1/8 hose back to the new ballast pump and valve system;

- replicated the original internal ballast pump and valve system for the fat sack ballast using 1 inch valves and tsunami aerator pumps;

- used 1 1/8 inch hose and quick connects to fat sacks (vent and fill/drain);

- used 3 way rocker switches for new ballast system - not yet hooked up since I need my electrical engineer brother to assist (electrical novice here)

- located bilge pump in front of V-drive with 3/4 inch vent hose to port thru hull vent outlet; connected electrical to original bilge wiring so the in dash switch controls both bilge pumps.

Once I complete the ballast switch wiring I'll test the system at the lake and report on it's performance.

[brad]

Additional photo's

[wakejunky]

NICE JOB 

keep us updated on your lake test

[brad]

Have done a few lake tests and subsequent modifications.  I couldn't get the water to flow both ways through the valves so I called the distributor, valves4projects in San Diego and they confirmed the valves are one-directional especially when you get into the 1" size.  My 3/4" valves on my internal ballast rebuild (according to Pete's directions) work fine on Fill but are slow to Drain (usually complete the draining process on the trailer).

Decided to add a second set of valves to the Wake Ballast system so I have one set dedicated to "Fill" and the other for "Drain."  It required another 3-way switch for a three switch system (1 for fill/drain, 1 for starboard fill/drain valves and 1 for port fill/drain valves).  I also dropped the pumps to ride lower because it's kind of a tight fit with my fresh water cooling system.  Had to pay attention to the steering mechanism so the Wake Ballast system didn't interfere.

Current performance--Fill of 750 lb fat sat around 5 minutes per side; Drain one side in around 7 minutes.  Haven't tried filling them both at the same time.  Ready to do some surfing with the flick of switch!

When the attachments are permitted again on this site, I'll post some pictures.

[brad]

New iteration of my wake surf ballast project!

I guess it just takes me multiple times of trial and error to get it right;-)

Since the valves were primarily one-way, it was difficult for the pumps to prime going the "wrong direction."  I added a second set of valves to accommodate the one-way nature of the valves but still had problems priming the pumps so I was having to manually empty or fill the fat sacks which defeated the goal of my project.  So this past winter I decided to try a new option.

The latest system uses Johnson Ultra Ballast Reversible Pumps.  I eliminated all the former valves and Tsunami pumps.  The rear ballast setup was pretty straight forward.  I ended up mounting the pumps on my fresh water system shelf next to the heat exchanger.  The spec's on the pumps recommend that they be mounted resting horizontally or vertically with the motor on top.  So I lined up the intake and output position of the pump with my hoses to the fat sacks.

The front internal ballast setup was a little more complicated since the pumps are too large to both fit in the cavity where the original system was located.  To solve this issue I ended up using a hole saw to access the cavity from the storage locker and placed the pumps in the storage locker.  Now that I've tested the system and it works great, I'll probably mount the front internal ballast pumps on the wall in the storage locker (where my sub amp is currently located).  Next winter I'll add another pump for a fat sack in the bow (either under the seats or a quick connect system like Wakejunky's).

Here is a pic of the double valve system that I ended up abandoning.

[brad]

New system pic's

[brad]

Some more

[brad]

Updated Switch Panel - purchased the breakers, panel and illuminated logo from newwiremarine.com.  They were great to work with in designing my customized panel (even added the USB plug).  Ryan was kind enough sell me his surplus level gauges since I broke mine when I pulled the original out.

[cyclone]

Wow that looks great and I'm sure it works well, after what you've been through Brad!! I've probably spent 5k on stupid ballast projects, that's one reason I bought an SX, figured I'd be good with a factory system, NOT!!

My valves seem to work well in both directions, sometimes one sticks and won't drain, break out the surfboard!

Incidentally, I somehow managed to lose the four button cover plate for the ballast system. If anyone has one, I would pay handsomely....  Or I'll have my kid make me one with his 3d printer:)

The one thing that bothers me in the back of my head about wakesurfing is if the engine oil pump pickup works properly at a 45 deg angle. Cars are designed to go up and down hills, not on the sides of them:) But, I guess if enough guys have done it for long enough without issues, than its probably OK. Did I miss any "I put a rod thru the block of my Epic wakesurfing!!" posts in the last coupla years? LOL!

Nice job on the ballast control panel Brad, I will have to check those guys out!

[brad]

Pete:  I have an extra cover plate.  I'll send it to you.  So glad to have you back on the forum!

[cyclone]

Brad that is AWESOME. I've been kicking myself for losing the darned thing!!

PM sent w/address

[brad]

Pete, face plate is on it's way USPS.

Let me know if you need anything else (from my box of extra parts)

[cyclone]

Likewise Brad, I've got a pretty impressive collection of parts from my various iterations of boat projects:)

Thanks so much, that panel has been gone so long I forgot what the buttons do!