Johnson Ballast Install on a 2007 OBV

Well, I finally got it started and let me tell ya, there is not alot of room in these boats. Rather than trying to wax poetically about the trials and tribualtions I thought I would share some pictures. Originally I had planned on using only 2 intakes for 4 Johnson pumps but after talking with Jason at Wakemakers he kind of talked me out of it as the intakes will not supply both pumps the required amount of water.

So even though I had already replaced the original scupper intake and added a second intake I know had to figure out how to get 2 more in there. I also want to add in the raw water strainer for the engine intake so I ended up doing this:

http://i702.photobucket.com/albums/w...g?t=1308584285
3 intakes on the starboard side and 1 on the port.

Here is another picture with the intakes, shut off valves and 1" hose attachments in place:
http://i702.photobucket.com/albums/w...g?t=1308584172

I almost crapped my pants when I drilled the 1st pilot hole beside the existing one as I had forgotten to take into account the scupper on the bottom (I removed the orignal and replaced it with a true 1" scupper to cover the holes) but luckily it fit absolutely perfect: (whew!)
http://i702.photobucket.com/albums/w...g?t=1308584069
Here is the other side:
http://i702.photobucket.com/albums/w...g?t=1308606169

More to follow.

Here are the hoses installed and the gas lines reconnected:
http://i702.photobucket.com/albums/w...g?t=1308584128
http://i702.photobucket.com/albums/w...g?t=1308584088

New 1" line running to the locker:
http://i702.photobucket.com/albums/w...g?t=1308584053

I had zero room for the pumps so I took this idea from a fellow member of this forum (thanks Chad) and it should work just fine.

Picture of 2 of the shiny new pumps:
http://i702.photobucket.com/albums/w...g?t=1308584143

Port side:
http://i702.photobucket.com/albums/w...g?t=1308583961

Starboard side:
http://i702.photobucket.com/albums/w...g?t=1308584032

This was 2 solid days of work to get this far. I had to stop as for the life of me I couldn't get the 1" hose to go over the supposed 1" fitting. I sent an email to Jason at wakemakers and he sent me a video clip as to how to do this. Hopefully it works! This is what I'm up against:
http://i702.photobucket.com/albums/w...g?t=1308583871

Now I have to get the overflow lines in and then wire up the pumps and I should be good to go.

Will post more pictures as I progress.

Looks great man! I'm really leaning toward these pumps myself.

looking real good so far

nice work. fun to work the ole 07 obv. stuff is tight. you took alot of stuff apart that i was scared to. let us know about the video. i had to boil my 1" to stretch it over the rule fill pumps, i had the black smooth hose.

Yes, nice work! Looks very clean so far. You have many of us thinking.

Looking good! What size intakes did you use?

Looking good! I still havn't mustard-up the guts to drill those below the water line holes in my boat yet. It's a psycological thing, I have the intakes, just need the nerves.

I had to boil my hose as well to get some of the fittings to fit, but I also have the smooth black like Jmvotto.

Are you going to fill the rear locker bags from the stern end or bow end?

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Originally Posted by jmvotto

nice work. fun to work the ole 07 obv. stuff is tight. you took alot of stuff apart that i was scared to. let us know about the video. i had to boil my 1" to stretch it over the rule fill pumps, i had the black smooth hose.

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Here is the link: www.youtube.com/watch?v=Ym1JrpDyJCE

Need a heat gun to make it work. i guess boiling would do the same trick.

Quote:

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Originally Posted by brain_rinse

Looking good! What size intakes did you use?

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Hi Brain, I used 1" intakes and 1" hose for the fill/drain lines. Overflow lines will stay at 3/4".

you don't need a scupper style on the bottom for the intakes, just a mushroom?

Quote:

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Originally Posted by 2007 Outback V

Looking good! I still havn't mustard-up the guts to drill those below the water line holes in my boat yet. It's a psycological thing, I have the intakes, just need the nerves.

I had to boil my hose as well to get some of the fittings to fit, but I also have the smooth black like Jmvotto.

Are you going to fill the rear locker bags from the stern end or bow end?

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To be honest the drilling was pretty easy. I would recommend using a 1/4" drill bit to do a pilot hole from the top and then get underneath to drill the 1" hole. I know everyone is scared to chip their gel coat but if you start the hole saw in reverse and also use some painter's tape you will get a very clean hole. I also used a dremel with a sanding tube to slightly open up the hole so that the mushroom fitting slides through easily. And if you do happen to chip the gel coat, the flange from the mushroom intake will more than likely cover it.

Just remember that you need to be at least 4-1/2" from center of the existing scupper intake in order to clear the scupper!

I am debating over whether to fill the rear bags from the front vs. rear. I think it would probably be better to fill/drain from the rear and then have the overflow coming from the top front, no? Seeing how you were my inspiration I'll defer to the expert and ask "what worked best for you?"

Quote:

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Originally Posted by viking

you don't need a scupper style on the bottom for the intakes, just a mushroom?

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Correct. The only reason you see a scupper on the bottom is because there was 1 there to begin with and I didn't want to have to deal with filling the holes from the screws from the original scupper.

also worth mentioning is that 4-1/2" center to center still gives you enough room to install the shut off valves. I had to remove the handles but that is easy enough to do.

I would be lying to say that I wasn't glad to be through the process though....

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Originally Posted by Canuckle Head

I would be lying to say that I wasn't glad to be through the process though....

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Working in the bilge is a pain, isn't it?! Actually working on most anything boat related is a pain. If it's not stuffed up in some impossible to reach location it's surrounded by unfinished fiberglass to tear up your arms. The end result must be worth it though or we wouldn't keep doing it! :)

What type of pumps did you use?

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Originally Posted by jester

What type of pumps did you use?

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Johnson Ultra Ballast Reversible Pumps........

Thanks so much for the youtube link. Getting the 1" fittings over is a PITA. If a next time I'd go back to the smooth tubing. I did the 'upgraded' and don't like them at all, plus the don't match my stock tubing.

I added a Johnson Ultra reverse pump via the 1" 'T' fitting from wakemakers that also feeds my ballast puppy (1" mushroom throughull). Not starved for water at all. The Johnson is much faster.

If you guys need more info, there's a writeup by a centurioncrew member that is overkill with all pictures and information needed. Made wiring a breeze for a novice like myself.

Quote:

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Originally Posted by sailing217

Thanks so much for the youtube link. Getting the 1" fittings over is a PITA. If a next time I'd go back to the smooth tubing. I did the 'upgraded' and don't like them at all, plus the don't match my stock tubing.

I added a Johnson Ultra reverse pump via the 1" 'T' fitting from wakemakers that also feeds my ballast puppy (1" mushroom throughull). Not starved for water at all. The Johnson is much faster.

If you guys need more info, there's a writeup by a centurioncrew member that is overkill with all pictures and information needed. Made wiring a breeze for a novice like myself.

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You are most welcome for the youtube link. Got a link for that centurioncrew thread? Please and thank you! :D

Looking good! What's the gph rating of the pumps?

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Originally Posted by cab13367

Looking good! What's the gph rating of the pumps?

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720 gph

http://www.wakemakers.com/johnson-ul...last-pump.html

Thanks Joe. So for fastest fill times, looks like the Tsunami T1200 is still the way to go.

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Originally Posted by cab13367

Thanks Joe. So for fastest fill times, looks like the Tsunami T1200 is still the way to go.

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I guess that would depend on if you have enough room for them below the waterline. In my case I do not and those pumps are not self priming.

I installed the Johnson pumps this spring and it has worked well with my 1100lb sac's.

Here is the over the top writeup: http://customfalconballast.blogspot.com/

and another one (has a link in it about someone who tested Actual Flow Rates of aerator and impeller pumps):
http://centurionavalancheballastinstall.blogspot.com/


FYI, the mayfair aerator pumps really do need to be below the waterline to prime (scupper and moving forward is a good way to prime if mounted high). 1200gph is good, but Duffy who is a big surfer on WW, just put a manifold system and Rule 3800 aerator pumps in. He went with 1.5" throughulls. He's filling about 1800lbs in 4 minutes.

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Originally Posted by sailing217

another one (has a link in it about someone who tested Actual Flow Rates of aerator and impeller pumps):

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I had to register with on the CenturionCrew forum just to read the referenced post, which had some really good data. I posted the important part of it here: https://forum.moomba.com/showthread....104#post232104