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Thread: restoration project: g40

  1. #1
    Join Date
    Nov 2005
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    restoration project: g40

    I'll admit that it looked a bit grim at the outset, but the challenge to see if I could breathe life into a pretty-far-gone ski inspired me to keep going.

    So... Karl Stall hooked me up with his old g40s for the cost of shipping (thanks, Karl!). I was super-psyched as I had been looking for a pair for a while but only met with ludicrous ($250+) asking prices.

    KS said they needed some work, and I was down with that. He was most concerned with a tail crack/delam.

    When I took them out of the box and looked them over, I wasn't too concerned with the tail....I was more worried about this:


    And this (dog not included with skis):


    The worst of the damage is not pictured, as they were already on the bench at that point.

    Stuff to address:
    • The *entire* length of the edges were rusted (not light rust, either)
    • There were some edge compressions
    • There were numerous core shots (with rust in them, too)
    • Various base gouges
    • Bases weren't flat
    • There was tape stuck to the topsheets and bases
    • The tail was cracked and delamming
    • There were a bunch of chips in the topsheets that needed to be repaired so no moisture would get in.


    I wound up putting quite a bit of time in them. The edges, a panzer file, and I got really cozy for a few hours. I was pretty optimistic as I saw (slow) progress....and eventually I was able to shave off enough of the edges so that the rust was gone.

    I got to work on the next big problem: the tail. With some cleaning, some 24-hour epoxy, and creative clamping, that problem was solved. It turned out to be one of the least intensive in terms of labor-hours.

    Base repairs are always fun; I knew repairing the coreshots would take a bit of time but not pose any significant problems. What took much longer was getting the bases flat. After having to shave away a bunch of the base edges, that resulted in a convex base. I did a ton of hand grinding to get them very close to flat.

    Next up was revisiting the edges to set proper base and side edge angles. They are now razor-sharp after hitting them with the panzer, file, and diamond stones. Solid.

    [The reason it took as long as it did was that the rust had to be removed and the base had to be flattened, but the two could not be done independent of one another to be properly addressed. I initially did some quick work to get the bases "sort of" flat, then had to go to town on the rust...but the amount of rust removed caused the edges to be "recessed". So...back to work on the bases to get them truly flat...and then yet another pass on the edges.]

    I structured the base and gave them a couple coats of wax (with hot scrapes to pull up the old stuff). I never polished the bases (left some on for the summer, to be scraped in the winter), so I don't have a shot that fully shows the bases and edges in all their glory. This shot (with the layer of unscraped wax) will have to do:


    They need a scarpe & polish when next season's first snow arrives.

    I cleaned the topsheets + removed stickers, epoxied the remaining topsheet chips, filled the old binding holes, and mounted some Fritschis.

    Again, I probably should have taken a better picture, but this is the only one I snapped after mounting the bindings last night:


    All told, I put quite a bit of work in these. Not including the binding mount, the project took about 10h (maybe more?). I didn't mind the work as I can't be out skiing, climbing, biking, etc., right now (although I probably should have been doing some projects around the house).

    Yes, it was a ton of work, for a hardpack, early season ski...but they still have a many turns left in them. Can't wait to ride them.

  2. #2
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    So the rain and snow is getting you down? Need a project Eh?

    Seriously though, looking good.
    Ski Shop - Basement of the Hostel



    Do not tell fish stories where the people know you; but particularly, don't tell them where they know the fish.

    Mark Twain

  3. #3
    Join Date
    Jan 2006
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    367
    Wow, nice job UAN. The edges on my G4s I picked up look like that, good to know that with enough work, they will hopefully look as good as yours.
    'Least I ain't chicken.

  4. #4
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    May 2002
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    Skis are so tough, well-made, and durable, it's amazing how easily they can be salvaged and rejuvenated with a little work. The visuals shold never be something to scare you away from a restoration project. Plus, it's good to get insights into how those things you spend so much time riding on are actually made. It's the fiberglass that makes them so tough. With fiberglass and resin, a bit of base and some glue, almost any ski can be brought back to life for at least a season's worth of enjoyment. Good job.

  5. #5
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    Nov 2005
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    S-I-J...It's sad, no?

    Since I can't be putting lines down in the Tetons, I need to do a "Tech Talk TR". Is that a board first???

    Below is another shot of the bases. There's still wax on the edges and the base hasn't been scraped/polished:


    A few folks have asked for FR+ pics... Here are another 2:
    (The "Powered by Titanium" bit cracks me up; reminds me of seeing folks on I-5 with "Powered by Acura" on their windshield...)



  6. #6
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    Nov 2005
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    Quote Originally Posted by J-Rad
    Wow, nice job UAN. The edges on my G4s I picked up look like that, good to know that with enough work, they will hopefully look as good as yours.
    Yeah...Splat's right. Enough loving can restore almost any ski. I did all the work by hand as it lets me get a better feel for what is going on with the ski. I also believe that the work is better than what you get from the average machine tune. (Improper stone grinds, I find, often result in work-hardened edges which are difficult to work with until they've been skied a bunch.)

    It took a bunch of time (waaaaay more than, say, tuning a new ski from the factory or doing regular maintenance, but I enjoyed it. It's rare to be so aggro with the panser & base grinding.

    Volkls are tough.

  7. #7
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    Quote Originally Posted by skiing-in-jackson
    So the rain and snow is getting you down? Need a project Eh?

    Seriously though, looking good.
    Oooh...it's not the weather, it's the knee that's keeping me inside.

    Time for the stationary bike.

  8. #8
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    Wow. I've got to start learning about that stuff.

    Much snow down there?

  9. #9
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    Nov 2005
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    Quote Originally Posted by corn dog

    Much snow down there?
    Down? You north of the 43rd parallel??

    Snow level is about 8K here in the Tetons. A squall probably deposited some good snow in the high peaks -- it was snowing at my place at el. 6,500 (a tiny bit of accumulation that went away as soon as the sun came out).

    I'm sure it's purdy up high.

  10. #10
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    Quote Originally Posted by upallnight
    Down? You north of the 43rd parallel??

    Snow level is about 8K here in the Tetons. A squall probably deposited some good snow in the high peaks -- it was snowing at my place at el. 6,500 (a tiny bit of accumulation that went away as soon as the sun came out).

    I'm sure it's purdy up high.
    Just up the road in Bozeman, 45th runs through YNP? Hoping to get to the tetons next weekend, a bit of a top up of the snow pack would be nice

  11. #11
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    Nice work.

  12. #12
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    Nov 2003
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    Nice job. What tool did you use for the base leveling? Did you use ribbon ptex for the edge core shots?

  13. #13
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    Quote Originally Posted by gforce
    Nice job. What tool did you use for the base leveling? Did you use ribbon ptex for the edge core shots?
    I like the SkiVisions tool. It's expensive (like $60), but I find it to be pretty accurate and good for both leveling and (with a separate stone) imparting a structure. That $60 includes a steel blade & a stone for medium structure. I like a more aggressive stone for dealing with extremely "base high" skis.

    I like the base ribbon, but most often (and in this case) I put down some metalgrip & then topped it off with ptex repair string. The string is a bit easier to work with than the ribbon and lasts plenty long in my experience. I used the metalgrip for repairs that expose the core and/or edges.

  14. #14
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    that is amazing work, UAN. you are a michaelangelo of ski tuning. you should see my bases. ruffled like a potato chip, because i was an idiot, and the edges are probably 90 degrees (our tuning equipment sucks). again nice work
    No longer stuck.

    Quote Originally Posted by stuckathuntermtn View Post
    Just an uneducated guess.

  15. #15
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    Let me know if you get really bored, say around September, and need more single, totally f'in blown out sidewalls, edge missing, shark bitten g40-41-4's....I've got a quiver in the closet.

  16. #16
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    Quote Originally Posted by skier666
    Let me know if you get really bored, say around September, and need more single, totally f'in blown out sidewalls, edge missing, shark bitten g40-41-4's....I've got a quiver in the closet.
    Hahahha. I need to take care of all of this stuff ASAP because I definitely DON'T plan on being on crutches in September.

    I should be climbing, climbing, climbing (or in SA/NZ, but that's looking less and less likely). No time for ski tuning.

    Long live the G4/40/41!

  17. #17
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    Ha! 666, you're right on track with my thoughts. I just went through the PMG blem pile and have a ton of brand new skis with bases on top of the edges in places, Sidewalls missing, delams, etc. Anyone wants a project, just pay shipping and handling.

    I gots some with topsheets crumbling off (topsheet bonding surface contamination). Those are mint mystery skis. Just fiberglass on the top.
    I'll either ski them or sell them cheap.

  18. #18
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    Oct 2004
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    ^^^ pm sent ^^^
    go for rob

    www.dpsskis.com

  19. #19
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    ^^ ditto ^^
    'Least I ain't chicken.

  20. #20
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    ^^^me too^^^

  21. #21
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    ^^same^^

  22. #22
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    ^^Done^^

  23. #23
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    May 2002
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    No longer taking requests for those blems.

    I'll get back to you guys later. Working on a press right now.

  24. #24
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    Nov 2005
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    Oh, man... I go to physical therapy for a few hours and missed this on my own thread?

    I totally would have gone for 179 blems. As you can see, I'm into projects.

    Oh well, enjoy folks that got in on it!!!

  25. #25
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    Mar 2006
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    i too would have been over the moon to get 179 blems, but the dog needed walking
    Three fundamentals of every extreme skier, total disregard for personal saftey, amphetamines, and lots and lots of malt liquor......-jack handy

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