Mercury Makeover

[GoneFission]

So the old Mercury Black Max runs like a top, but the stator charging system won't keep up.  It's 16 amps max, but not much at idle, not even enough to keep up with electronics, pumps, stereo, etc...  So some checking around and I find out Simon Motorsports has a kit to put a 50 amp alternator on the 2.4/2.5 Merc!  Only problem is - it won't fit under the old clamshell cowl - you gotta have the Alien cowl.  So the lovely Betsy semi-surprises me at Christmas with an alternator kit and cowl!!  Last week it all got installed (yes, took a while, work too much)  First, the Mercury 60 degree V6 is an amazingly compact engine for the output:
 

To install the cowl, the powerhead has to come off:


Of course, you know you will find other things that need fixin' - like corroded bolts that need stainless replacements:


Next, scrape the gasket surfaces (Scott knows how to do that now), install new gaskets, and put the powerhead back on - note the blue Merc lube on the driveshaft and studs:


The new cowl and setup required re-route of the telltale/flush port:
 

The new alternator setup is a nice, clean setup - it requires the 3-piece flywheel - if you've got the single piece, Simon will send you a 3-piece for free if they have one laying around or will sell you a go-fast lightweight flywheel  
 

Another view of the install:


And them put the new (for me) cowl on - and the Mercury Makeover is complete!  

[fitz73222]

Wow! Very nice install John.

Very nice of Betsy to put it on her AM EX.. Those are some "proud" components! So you just disconnect the existing stator and voltage regulator leads? Any other mods? So it looks like the lower cowling just drops over the mate up surface between the powerhead and exhaust adapter? I'm going to assume that is aluminum and then the fiberglass lower cowl is screwed to that plate The kit comes with longer head bolts for the support casting? So for the 3 piece flywheel, you just unbolt the center hub bolts and bolt the new pulley hub on top assuming its cleared to be able to use the standard flywheel puller should the flywheel need to come off for service? Very nice looking system and nice install. Good job!

[RickK]

That's a big change in charging John - I'm sure you'll like it, especially for keeping the batteries up without having to get up on plane for a while  
What was the cost of the kit?
How much wider is the Alien cowl vs the old one?

[gran398]

Sweet!!  

Love that Alien Cowl! Them Brunswick County Boys ain't gonna believe their eyes this fall....."Man... Bubba.....did you see DAT????"

[GoneFission]

Wow! Very nice install John.

Very nice of Betsy to put it on her AM EX.. Those are some "proud" components! So you just disconnect the existing stator and voltage regulator leads? Any other mods?
Actually, all the old stuff stays as-is.  The new system operates over the old system.  So actual max current is the old stator system plus the new alternator system.  The alternator has a built-in voltage regulator.  

So it looks like the lower cowling just drops over the mate up surface between the powerhead and exhaust adapter? I'm going to assume that is aluminum and then the fiberglass lower cowl is screwed to that plate.
That's right, the cowl has a couple million screws that hold it to the lower mounting plate, which gets gaskets on both sides.    

The kit comes with longer head bolts for the support casting? So for the 3 piece flywheel, you just unbolt the center hub bolts and bolt the new pulley hub on top assuming its cleared to be able to use the standard flywheel puller should the flywheel need to come off for service? Very nice looking system and nice install. Good job!

Yes the kit comes with 2 longer head bolts that get the same 40 ft-lb as usual.  It also comes with 8 grade 8 longer flywheel bolts to mount the pulley which get 30 ft-lb torque as usual.  Yes you can remove the flywheel using a standard puller and get a socket over the crank nut for the 100 ft-lb torque.  

[GoneFission]

That's a big change in charging John - I'm sure you'll like it, especially for keeping the batteries up without having to get up on plane for a while  
What was the cost of the kit?
How much wider is the Alien cowl vs the old one?

The Simon kit is $575 - about the same as a Merc alternator:  http://www.simonmotorsports.com/2.5alt/2.5alt.html  
The Alien cowl looks to be about 3" wider than the old clamshell.  

[Georgie]

John, that looks amazing!     Wish OMC/BRP would offer something like that for my crossflows....

Just to be clear, was your OEM system actually failing/underperforming, or do you have so many peripherals that you just wanted the output at idle to be much greater than what the stock system could provide?  Either way, that's a REALLY neat aftermarket option.  

[wingtime]

Bitchin' !  I love the look of those alien cowls.  Wicked mean looking!

[GoneFission]

John, that looks amazing!     Wish OMC/BRP would offer something like that for my crossflows....
Just to be clear, was your OEM system actually failing/underperforming, or do you have so many peripherals that you just wanted the output at idle to be much greater than what the stock system could provide?  Either way, that's a REALLY neat aftermarket option.  

The Mercury stator-based OEM system puts out a max 16 amps at speed, but at idle, it will not keep up with radios, stereo, sonar, and a livewell pump.    :x   So if you are trolling, you've got to stop occasionally and run somewhere to get the batts charged back up.  Da mota does not care - it will run without the battery, cuz the ignition fires off the stator.  But it's a PITA when you've been trolling for a couple hours, then you push the transmit key on the radio and the low voltage alarm goes off on the sonar.  Then you check the volts and there you are a 11.0...    

[seabob4]

That is a sweet little set up there John.  Now if they would just make a 60A bolt on kit for a 75 horse...  

[Georgie]

Cool!  Thanks for the info!  

[GoneFission]

Betsy does not like the yellow/orange on my boat...  OK, here are some new Alien decals I found - in colors that are more like the boat - and in the very rare 2.4 versus 2.5!  See what you think:

[Georgie]

I agree with Betsy!  

Blue looks MUCH better than orange and yellow on the water   ... unless you're running one of those psychedelic GO-FAST boats that make your ears ring for days.    

[wingtime]

Thats a tad too much orange.  The graphics you found will look better on your boat.  i see you upgraded to a EFI at the same time!  

[gran398]

I'm with Miss Betsy