How To - Metton Hull Repair

Parts Needed, Tools Needed, Step-By-Step, Notes, The Damage, The Fix

Topic:                           How to fix Metton Hulls - Non Structural Fixes

Expertise Required:      Intermediate

Estimated Time:            An afternoon

Parts Neeed:               You will need the following parts:

      • Your brain
      • JB Weld
      • Flat Black Paint

Tools Needed:             You will need the following tools:

      • Putty Knife
      • 90 Degree air grinder
      • Various Clamps
      • Backing Material (flat pieces of aluminum, ruler, paint stick, etc)

Step-By-Step:             Here's step-by-step instructions on how to get it done:

  • Step One - Remove the pump/ski from the bike - it will save you hours. Before you do, reach in and see if there's excessive play in the shaft (that would allow the impeller to contact the wear ring). It might be time to replace the nozzle bushing and seal.
  • Step Two - 


Saltwater use dictates that all raw aluminum surface need protection. Not so necessary on the impeller but very necessary for the pump and nozzle inner surfaces. Here's some of Wbbrian's work

The Damage:                  Apparently the owner of 2 of the bikes I purchased in Boston wasn't aware that the motors can be removed without cutting the hull to clear the exhaust can.

So . . . he took a jigsaw to the hulls and cut them. Here are a few pics of the damage.

The Fix:                       Luckily the cut off pieces were just laying in the bilge and I was able to re-use them. I first took the time to get some backing in place to hold the pieces and then used JB-Weld (Epoxy) to rebuild the damaged areas. Once I sanded the areas back down flush and then shot some flat-black paint on there it's hard to tell there was significant damage. Here's a few pics:

Here's the other bike . . .





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