Ballast Upgrade on a Budget

[cab13367]

I wanted to upgrade my stock ballast system without drilling any additional holes in the boat, reusing as much of the stock stuff, and keep the cost down. I only run 1310 lbs of ballast (455x2 + 400) for wakeboarding and 1150 lbs for surfing (750x1 + 400) so I didn't want/need to go all out with three T-1200's on separate 1" intakes.

So this is what I decided to do:

- Replace stock 3/4" intake with 1". Use 1" tees and valves.
- Install one pump per bag - a Tsunami T800 for the starboard side rear locker, another T800 for the ski locker and the stock Rule 1200 gph pump for the port side locker since this is where we use the 750 lb sac (for surfing).
- Reuse 3/4" fill hoses for the T800's, use 1" fill hoses for the Rule since the Rule outlet is 1".

I did the install this past week and lake tested it today.

With the stock system, my fill times were:

- 14:55 for all three sacs (1310 lbs)
- 13:06 for just the 750 lb sac

With the upgraded system, my fill times improved to:

- 8:58 for all thee sacs (1310 lbs)
- 6:00 for just the 750 lb sac

Instead of using vented loops to prevent auto filling or auto draining at speed, I used brass swing check valves for the rear bag fill lines and just a looped hose for the front bag (admittedly, not as high a loop as I wanted) so I am having some issues with auto filling/auto draining that I need to sort through.

UPDATE: I installed a 3/4" Irritrol 700 Ultra Flow valve and this fixed my auto drain and auto fill issues with the front sac. See pg 5 of this post for pics and description.

Overall, I am super happy with the results, especially with the 6 minute fill time of the 750 surf sac!

Now for some pics:

This is the stock 3/4" intake. Note that it steps down from 1" so I did not have to enlarge the hole to install a new mushroom type 1" intake.


New 1" intake, 1" tee. and 1" full port ball valves installed. Note the 1" to 3/4" white plastic bushing installed on one of the valves to allow the 3/4" intake of the pumps to thread into.


Here you can see the Rule installed on the ball valve at the bottom of the pic, and a tee installed at the other ball valve with two T-800's attached to the tee. You can barely see the T-800 to the right of the tee, under the large raw water hose.


Here's a shot from the other end. You can see one T800 under the motor mount and another to the left under the large raw water hose.