In June 2023, I began restoring a 1986 MasterCraft Pro Star performance ski boat powered by a marine 351 Ford Windsor V8. After years of inactivity, the engine had developed multiple electrical and fuel delivery issues. Working with my grandfather and sister, I led diagnostic and repair efforts across yearly two-month summer windows, using vacuum and fuel pressure gauges, a multimeter, and leak-down testers to trace failures in the ignition and fuel systems. The project is ongoing, with a fuel tank flush planned for winter 2025 ahead of testing the following summer.
Ignition and Timing Systems
- Diagnosed and optimized ignition timing across various distributor configurations
- Cleaned and replaced spark plugs and leads; rewired the ignition coil system without an inline ballast resistor, accounting for the component's electrical properties
Fuel System Restoration
- Tuned the accelerator pump and fuel delivery response; adjusted the air-fuel mixture using aerodynamic and combustion principles
- Rebuilt and chemically cleaned carburetor jets and bowls; replaced the mechanical fuel pump and calibrated fuel pressure using inline valves and filters
Cooling System Repair
- Replaced and resurfaced a damaged Indmar marine water pump; refinished the crankshaft after a bearing race failure
- Used thermal expansion techniques to extract brass seals; reassembled, lubricated, and tested pump operation at high RPMs
Top to bottom: Full vessel, engine with old carburetor, running engine with new carburetor, damaged water pump.