I opted to use the Loctite PL S-30 Polyurethane sealant over the 3M 5200 because it holds it shape much better when dispensed from the tube. Thanks guysTom- my plan is to glass the whole rear section in from one side to the other.Unfortunately I got side tracked this week. The Funjet has a hole in the bottom of the boat that matches the bottom of the pump then the nozzle is sealed through the rear of the boat. Well, I needed to fix a problem with the spoolgun on the welder, but once I got that done I laid down some decent welds to get the doghouse mocked up.
I started with a non working 90' seadoo with a swapped 89' 587 (didn't know that at the time) Tore down the motor and did a top end rebuild. Got tired of lifting the pump and motor in and out of the Jon so I had to build a overhead winch system. I don't know what this guy did to patch up the bottom, but its a mixture of some hard epoxy and roofing tar that I was constantly lighting on fire.

The spoon was really bothering me and I didn't have a clear idea on how I wanted to make it. I was also not comfortable with the amount of flex it would retain after cured, since fiberglass and aluminum would have different expansion rates I wanted something that would remain flexible. Like painless tom, I have close to 1000 miles on the inland rivers of SC on my boat, and who-knows-how-many miles out here in the saltwater marshes, with plenty of days of riding in choppy water, plenty of hitting boat wakes, doing 180 spins, and anything else that could put tremendous stress on a hull.
I plan on taking a retractable extension cord and mounting it at the one end and remove the brake so it moves freely. I think that is why the one side was coming out so poorly with the welds because it was contaminating the weld. 3M 5200 gets harder than the PL S-30.I hope you plan on bedding in the jet ski hull with fiberglass once you've joined the two hulls together, you will need lots of reinforcement in the motor mount area, and where the hulls are joined. I didn't get great pics before I shut off all the lights, but this should give a decent idea.

If you don't glass all of that in, extending the footprint out to the width of the jon boat, the union will flex and leaks will develop. I'll admit its fairly trivial, but I wanted to make sure everything fit nicely so it took some time. This will allow me to flex the pump plate up and out of the way when it comes time to ever need to remove the pump itself, since it needs to drop out the bottom for removal. I built my jet jon almost 2 years ago, and close to 1000 miles so far, without a single problem.

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