Yes the craze has hit me too, I started a few months ago sourcing a ski and trying to get everything in order to get started. Had two weeks off and was able to get some stuff done. Seems to go together very nicely. A jig is a must in my opinion. Here are some photos. Hope these help anyone looking build one. Any and all input is appreciated. $1400 for aluminum (3/16" bottom/transom 5086)(1/8" sides 5052), $200 for waterjet cutting. $125 for bending.
Eventually required welding tabs on and C-Clamps, rubber clamps just didn't cut it.
Finally sitting in the jig right.
Tacking it together was fairly painless, everything seemed to fit right with just a little adjustment.
Deck combing and gunnels, had to cut one gunnel cuz I screwed up and bent them both the same direction...ID10T
Underside prior to the final welding, had to weld on tabs to the bottom to suck it to the jig before the sides were installed. ADVICE to newbies like myself. Build a jig, makes your life a lot easier, I would have had no idea that it needed to be sucked down without the jig showing me. how far off it was.
Everything is welded in and out except the bow deck and the windscreen, need to cut the ski apart when I get back into town and figure out some measurement for stringers and motor mounts. I'll have another two weeks so hopefully I can get some more photos up when I get back.