Honda CBR 600cc 10x6 Aluminum Airboat Build

Airboats with smaller powerplants.
Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sat Aug 04, 2018 12:23 pm

It’s been a little bit sinc my last post but I have made a fair bit of progress since then.

I finally made enough room in the garage to slide the boat in. The engine stand was starting to rust a little from sitting outside even with a tarp on it. Not being a big fan of cleaning and prep work prior to painting i didn’t want the seat stand or the cage to start rusting. I hit the cage with some primer to protect it until I’m ready to work on rudder mounts.

I have pretty much finished the seat stand. The front seat will be removable. I mounted the gauge console on the floor because it was pretty clunky looking on the side of the seat stand. It just seemed practical there; low CG, out of the way, short wiring runs, etc.

Using expanded aluminum for the floor and driver seat basket as well as for chain guards. All the aluminum is bolted down with 1/4-20 bolts which requires a ton of mounting tabs. I have made a bunch already by drilling twice and cutting with a sawsall. I underestimated how many tabs it would take but I have a friend with a shear and a punch and die so I was able to cranck our 48 1”x1 1/2” tabs with a 5/16” hole in about 30-45min. I still have a little more work to do with the chain and sprocket guards and a guard for the prop shaft.

I picked up some aluminum to build a gas pedal assembly and after that I need to start thinking about rudders ad mounting.
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John Fenner
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby John Fenner » Sun Aug 05, 2018 9:08 am

Interesting build, following to see the final outcome, you are doing very clean work!!
I never finish anyth,,,.

Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sun Aug 19, 2018 5:22 pm

I added a little safety to the prop shaft area to prevent entanglement and just in case something cut loose.
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Mon Sep 03, 2018 7:11 pm

Just about finished building a gas pedal, it’s still has some finishing and I need to make the cable holder for it. I found a good side profile pick of an airboat gas pedal and went with it. It’s probably a little over engineered but better that than under.

I have to order some more clutch and throttle cable parts to get those sorted out. I also have 2x stainless uhmw pillow block bearings coming for the rudder stick.

Trying to figure out what to do with the exhaust....
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Thu Sep 20, 2018 12:01 pm

I finished up the gas pedal with a few minor tweaks of the geometry to get the pedal travel I was looking for and built a new throttle cable.

Mounted some uhmw pillow blocks to hold the rudder stick.

Shortened the stock muffler about 6” so that it will fit in the cage a little better. Still need to mount th muffler in its final location.

The trailer that came with the boat originally sat reall high and had some rotted out springs so I put new springs, u bolts and a 2” drop axle. It still wasn’t as low as I wanted It so I whipped up some rollers.
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Thu Sep 20, 2018 12:09 pm

With the trailer fixed up I was able to pull the boat out of the garage and throw it into the pond for the first float test with all the weight of the engine and stand, cage and seat stand.

I could not have asked for it to float and better than it does. I can stand on all around the boat and only at the back by the cage does the very corner of the deck get wet. I had my wife get on with me and it floats rock solid and stable.

This was a huge gamble as I never tested the hull to see how much weight it could handle and it looks like it has worked out in my favor.
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sat Oct 06, 2018 3:50 pm

I cut up and shortened the stock muffler about 6-8” and put it all back together and welded a bracket to the cage and use the original exhaust hanger but upside down to mount the pipe. I cut and rotated the fitting at the headers to get the curve in the flex pipe that I wanted. And that pretty much took care of the exhaust situation.

I welded a couple tabs at the top of the cage for a collapsible running light as well.
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sat Oct 06, 2018 4:01 pm

I spend a lot of time thinking about something before I do it so that I don’t have to undo it or redo it but it inevitable that you will. I originally welded the bracket for the bilge pump on the right starboard side of the hull before it had slick bottom on the hull and it was decked over. Well it wasn’t going to work where I had it because of the exhaust and the parts i had to work with. I welded a new bracket on the left side and tried to cool everything quickly to prevent damage to the slick bottom. Luckily I only browned it in a couple spots. Due to the type of bilge discharge fitting I had to run a piece of tubing out the back and that was what I was worried about it melting from being close to the exhaust. I had been nervous to drill a hole in the deck until I knew I had the right spot. So all worked out well and now I’m starting on making some rudders. Just picked up the material and will update as it comes together.
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Air canada
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Air canada » Sat Oct 06, 2018 9:13 pm

Boat looks awesome can't wait to see vid of it rocking
:canada:

Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sun Oct 07, 2018 7:16 pm

Thank you. I am pretty happy with how’s its coming together. Here are the rudders I cranked out over the weekend. They are 32” x 18”. Center of pivot is 6”. They have a piece of tubing inside that is a about 7/8” OD. The leading and trailing edges are welded up and the end plates are just tac’ed as of now. Top plate is 1/8” and botttom is 3/16 because that is what I had material to do and I figured the extra thickness would be good for the control linkages.

The rudders took a lot less time than I was anticipating so I need to catch up on my planning. I was going to start on rudder mounts first but now I’m not sure if I want to start on the prop shaft adapter first. To be continued.
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Thu Oct 18, 2018 7:59 pm

No major advances due to my wife and I’s anniversary but I did finish welding the ruddr end caps and I’m really happy how they turned out. I am going to try and pick up some metal tomorrow for rudder mounts on the cage and I also need to track down a piece of steel for the prop shaft adapter.
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Wed Nov 14, 2018 9:42 pm

I found oil imbedded bushings from McMaster Carr that were almost a perfect fit. Just some minor sanding of the aluminum rudder tubes i.d. and the bushing i.d. I also picked up rod ends to make my own linkage. I thought I was going to be able to thread a piece of half inch stainless with a die and I was wrong. It is really hard. I couldn’t hold it tight enough to keep it from spinning in my vise even with vice
grips on it as well so I found I could also get pre threaded rods.
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Wed Nov 14, 2018 9:56 pm

I also got a teleflex cable and set up the linkage locations after a lot of testing to make sure it was where it needed to be. In hindsight I wish I went with dog leg stearing instead but it’s a done deal at this point.

I started cutting in the wiring harnesses to remove the excess that I wont be using and working on bypassing the safety switches. I was going to try and use some of the existing wiring for lights but I don’t think it’s worth the effort.
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Jssflyer
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Jssflyer » Thu Nov 15, 2018 11:40 am

Wow, muckduck. That has been quite the project. Your getting sooo close! Fanatastic to see it all in 30 minutes what took years to scrub, rub, and dub. Awesome job, clean design, tastefully done.

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Waggs
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Waggs » Sun Nov 18, 2018 12:42 am

I had the same problem when trying to thread stainless rod for my linkage. I used the top jaws out of two of these pipe wrenches and my vise with the vise pressing the “tops” of the jaws pinching the rod. They bit nicely, almost need 4 hands to set it up though.
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Thu Dec 13, 2018 10:26 pm

Great tip Waggs!

Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Thu Dec 13, 2018 11:06 pm

I decided I didn’t like the light switches and everything being out of reach so I built an aluminum box with a lid to hold everything except the ignition key which I also made a cover for to prevent it from being damaged. I made a flag pole holder out of some 1/2” square tubing and a couple nuts and bolts and welded that to the top of the cage.
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Thu Dec 13, 2018 11:22 pm

I picked up a 6” diameter 4” long piece of steel for around $105 to make the prop shaft adapter. I really should have gotten a 5” piece and it would have saved me a lot of time machining but it will be good practice. I also made some handles for the driver and pasenger seats. Until I have a good day to spend at my friends meal shop machinging I picked up some gloss black paint for all the metal work. The aluminum guards and seat stand decking are going to stay aluminum. I am going to put down a light blue seadek but leave the rivets on the deck exposed and Im undecided whether i want to paint the deck of the hull a gray color or just leave it aluminum. I’m leaning towards just cleaning up the aluminum a little. I’ve started tearing down the seat stand and doing the final welding sine most everything was just tacked. That way I can start priming and painting as well.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Wed Dec 19, 2018 6:44 am

One of the most important features to add was a bracket for rod holders. I went with 4 figuring 2 gigs and 2 poles between 2 people. I tore down the seat stand, final welded everything and got it primed with 2 coats and 2 coats of gloss black. I’m thinking I will do one more coat of gloss black. I am reall happy about how the expanded aluminum will look against the metal work. I also started tearing down the cage and engine stand for final welding. I decided I’m going to save the adapter for the very end.
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Sniper » Wed Dec 19, 2018 8:17 am

I really curious to see how this boat preforms after you get it finished, you have certainly done a nice job on it so far though
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sun Dec 30, 2018 9:10 am

Thank you Sniper! You and me both! It would be pretty devastating if after all the time (over a year) and money (way more than initially anticipated) it ends up running like a turd. Only time will tell but I am getting dangerously close to having it up and running and it feels good to be on the home stretch. Build update to follow shortly.

Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sun Dec 30, 2018 9:20 am

I tore the boat down and was really pleased that my design did allow the engine to be easily removed with out cutting and welding. It was untested until now. I primed and painted all the metal work gloss black and have started to reassemble. I am using staineless steel lock nuts, bolts and washers everywhere I can except a few areas use grade 8 hardware. I have also polished all the aluminum including the deck of the boat using scotch bright pads for a 4 1/2” angle grinder and just doing some general cleanup including sharp edge and booger removal. She is really coming together. So far all the forethought I put into the design is paying off and there have been minimal hiccups. I am working on more of the wiring and will add some more updates on that. Merry Christmas and happy new year!
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sun Dec 30, 2018 7:33 pm

A few shots of wiring in progress. It’s coming together nicely but not exactly as I had planned. My 6 circuit fuse block didn’t fit into the box with all the switches and I didn’t want it loose in the main console. I figured I wasn’t going to use the area where the ignition key was and the fuse block fit there and I already had a hole that used to have a momentary switch which was perfect to run the wiring through. Not ideal but it works and I am shrink wrapping and putting dialectic grease on all connections.
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sun Jan 27, 2019 7:54 pm

I got a boat assembled and wired. It came together pretty well with no real hiccups.
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Muckduck
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Re: Honda CBR 600cc 10x6 Aluminum Airboat Build

Postby Muckduck » Sun Jan 27, 2019 8:06 pm

I made it over to my friends shop to turn and drill the prop adapter and weld the shaft to the adapter. If you are in the Sarasota area and need metal, welding, light machining or trailer parts, Hoover Welding at fruitville rd and 75 (941)-893-7564 is the place to go. Reuben Hoover has been awesome help and supplied all the materials for this build.

I am pretty happy with how the prop shaft adapter turned out. When I bough the piece of material to make it out of for whatever reason I thought I needed a 6” diameter piece. Well when I got home all I needed was a 5” diameter piece. I really under estimated just how slow of a process turning metal was. I probably spent a solid 12 hour day turning and drilling but I got it done. Im pretty good at welding but I had Reuben weld it because he knows the feel of his machines better and could get it done right the first time. Plus I told him he has to warrant it now haha. I installed the shaft and prop and guessed at a good starting point on the pitch for the prop. I had to order new clutch plates after it sitting for so long so those should be in tomorrow and I am going to install an additional spring loaded chain tensioner. The first run is dangerously close.
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