Classic AquaSport
Aquasport Mechanicals - things that need a wrench, screwdriver or multimeter => Engines & engine woes => Topic started by: gran398 on February 09, 2013, 09:27:32 AM
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Guys, Fitz did a tremendous job on the 75 Mercs. He taught me a lot too, and I'm very appreciative.
THANKS Farley :thumright: :thumright:
I thought I'd share what was accomplished. What really impressed me was the organization of parts, cleanliness of the work area, and processes. Nothing was ever "forced" or beat on.
Here are a few pics to start:
(http://www.classicaquasport.com/gallery/data//500/IMG_1579.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6531&title=img-1579&cat=500)
(http://www.classicaquasport.com/gallery/data//500/IMG_1580.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6532&title=img-1580&cat=500)
(http://www.classicaquasport.com/gallery/data//500/IMG_1581.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6533&title=img-1581&cat=500)
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Thanks Scotty,
I don't have the rest of the pictures here...They're on my laptop at work;so post away if you would. What we had to do to these engines is a perfect example of why it is so important to do annual maintenance. These engines are 2004 vintage and the gearcases had never been off. These lived in South Florida salt and it showed. Our goal was to rebuild all 6 carbs, add the extension housings to make these 25" shafts for the new transom height, install complete water pump kits, grease,gearlube and fire them up before we went to Bobs. Weeks before Scotty came down my only apprehension was the potential for stuck gearcases. Well the apprehension became real. On some Mercury models they use studs and nuts to secure the gearcase to the midsections. Salt can accumulate between the stud clearance holes and studs. These were literally welded with salt impaction. Heating the area around the stud did nothing. Some people resort to prying and beating on the case to get them loose and wind up damaging the gear housing and midsection mating joint. So I partially reinstalled the nuts on the studs and with block of wood and a prybar tried to walk the gearcase off of the studs by pushing upward on the nut and pushing the gearcase down. That got me about 1/16 of an inch after about 3 hours. So I decided to pull the powerheads and get crankshaft out of the driveshaft spline so I could rock the lowerunit front to back, combined with heat and prying they eventually came off after about 6 hours on each unit. My goal was to not damage these engines for many reasons besides we needed to maintain a flat unbuggered surface to mate up the new 5" extension housings. While I was dealing with these stuck gearcases; we called around for powerhead gaskets to no avail and finally found them ay my friends down at Funtime Boats in Merritt Island. So Scotty drove the 150 mile round trip and brought back 2 gaskets. The pictures show what we dealt with when we started to work on the water pumps. I've never seen waterpumps this full of salt. Completely encrusted, finally got them apart with more heat and patience. Didn't break one bolt luckily.
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South Florida? :scratch:
Are the twins the offsring of Ms. Marco?
Once Encrusted, Now Loved. :cheers:
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South Florida? :scratch:
Are the twins the offsring of Ms. Marco?
Once Encrusted, Now Loved. :cheers:
Yep,
That be them. So the engines went from Marco to NC and back to Brooksville. Miss Marco went from Marco to NC and back to Port Ritchey. Me And Scotty saw her in the back of a shop on the ground and being scuttled for parts. The bow deck was being put in a Proline.
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Ah, the Virgin Miss Marco. Pure as the driven snow. Spent her life indoors.
Used only once.....to take his wife to church :salut:
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ive seen stuck gear cases more than a dozen times at the marina. them mercs love to put up a fight :lol:
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Fellas, Farley began my apprenticeship showing the proper technique to remove old gaskets. My first job was "Gasket Scraper."
Then I moved up to Torch Man. Finally, I was a Torque Wrench Man.
He did a helluva job.
More pics in chronological order:
(http://www.classicaquasport.com/gallery/data//500/IMG_1582.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6534&title=img-1582&cat=500)
(http://www.classicaquasport.com/gallery/data//500/IMG_1583.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6535&title=img-1583&cat=500)
(http://www.classicaquasport.com/gallery/data//500/IMG_1584.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6536&title=img-1584&cat=500)
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This is my first assignment
(http://www.classicaquasport.com/gallery/data//500/IMG_1589.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6541&title=img-1589&cat=500)
After 12 hours of heartache....both LU's off
(http://www.classicaquasport.com/gallery/data//500/IMG_1591.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6543&title=img-1591&cat=500)
Farley showing his appreciation :mrgreen:
(http://www.classicaquasport.com/gallery/data//500/IMG_1592.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6544&title=img-1592&cat=500)
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Show us more Uncle Scotty! This thread will be dead by Sunday night! Post the damn pictures...
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More Pics Scotty! you on dial up or something? :lol: Overall the motors look like they are in pretty good shape.
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Awesome job on the mating surfaces Scott! You know Farley, in regards to Scott's boat, I'm glad I'm not you. But, if you took a good "inside" look at the Glacier Bay that showed up today, well, I'm sure you'd say you're glad you're not me!!
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Show us more Uncle Scotty! This thread will be dead by Sunday night! Post the damn pictures...
Oh Noooo....we're just gettin' rollin' brothers.
Gotta "Whole Lotta Love" left :thumright:
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PS...ya'll look at my younger brother showing the love in that last pic.....man...that's de chit right there :salut:
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Carb rebuilds:
(http://www.classicaquasport.com/gallery/data//500/IMG_1593.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6545&title=img-1593&cat=500)
(http://www.classicaquasport.com/gallery/data//500/IMG_1594.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6546&title=img-1594&cat=500)
Port side LU, prepping for Bay Manufacturing 5" extension kit:
(http://www.classicaquasport.com/gallery/data//500/IMG_1595.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6547&title=img-1595&cat=500)
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Hoods, midsection covers:
(http://www.classicaquasport.com/gallery/data//500/IMG_1596.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6548&title=img-1596&cat=500)
The heat is on...breaking corrosion on original water pump housing:
(http://www.classicaquasport.com/gallery/data//500/IMG_1598.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6549&title=img-1598&cat=500)
The reason for scheduled LU maintenance:
(http://www.classicaquasport.com/gallery/data//500/IMG_1599.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6550&title=img-1599&cat=500)
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To the right are two circular areas. These are bolts encrusted with salt. All bolts were dug out clean with a picking tool, air-blasted, and sprayed with WD-40:
(http://www.classicaquasport.com/gallery/data//500/IMG_1600.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6551&title=img-1600&cat=500)
After excavation... and rebuild....fresh water pump and housing, ready for install:
(http://www.classicaquasport.com/gallery/data//500/IMG_1601.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6552&title=img-1601&cat=500)
Prepping for the LU extension kit install:
(http://www.classicaquasport.com/gallery/data//500/IMG_1602.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6553&title=img-1602&cat=500)
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Ah, the Virgin Miss Marco. Pure as the driven snow. Spent her life indoors.
Used only once.....to take his wife to church :salut:
That's funny - sorry to laugh at your expense but that old man was such a liar. May he slow-simmer in hell with a job of replacing water pumps for eternity.
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At least the good news is that everything that needed to be replaced was replaced and all the bolts and studs were loctited or coated with Mercury Perfect Seal, torqued and will come apart 5 years from now. Scotty got to see how these engines are put together and got a good education about how to do things right so when he gets them serviced in the future he'll know what the tech is talking about.
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(http://www.classicaquasport.com/gallery/data//500/IMG_1603.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6554&title=img-1603&cat=500)
Changing thermostat
(http://www.classicaquasport.com/gallery/data//500/IMG_1604.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6555&title=img-1604&cat=500)
Installing longer LU studs
(http://www.classicaquasport.com/gallery/data//500/IMG_1605.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6556&title=img-1605&cat=500)
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Mounting powerheads
(http://www.classicaquasport.com/gallery/data//500/IMG_1607.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6557&title=img-1607&cat=500)
(http://www.classicaquasport.com/gallery/data//500/IMG_1608.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6558&title=img-1608&cat=500)
Jackleg installed linkage, port side
(http://www.classicaquasport.com/gallery/data//500/IMG_1610.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6559&title=img-1610&cat=500)
Starboard side
(http://www.classicaquasport.com/gallery/data//500/IMG_1611.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6560&title=img-1611&cat=500)
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How long had these motors sat? Most people would have used a BFH(big f-ing hammer) to get them loose and probably broke a few things in the process.. :x You guys did a great job of cleaning up the lower cases :salut:
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In one way you guys were lucky :scratch: . At least you could get the power heads off. I’ve seen them so bad, you couldn’t get them off. The spline of the drive shaft was so corroded into the crank shift, that it wouldn’t come off. That’s why heat PB blaster and never seize have become my best friends when working on motors used in salt water. :thumleft:
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Farley showing his appreciation :mrgreen:
(http://www.classicaquasport.com/gallery/data//500/IMG_1592.JPG) (http://www.classicaquasport.com/gallery/showphoto.php?photo=6544&title=img-1592&cat=500)
Perfect :lol:
Bill
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Sorta like this? (http://i259.photobucket.com/albums/hh301/seabob4/Smilies/Smiley.gif)
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Because of their past life do you think these motors would be a candidate for Mr Demeanor's vinegar in a drum treatment? I don't think it would hurt and could possibly get the water passages really cleaned out where you guys couldn't get to.
Link to Demeanor's thread, actually a really good read!
http://www.thehulltruth.com/boating-for ... negar.html (http://www.thehulltruth.com/boating-forum/368827-how-cleaning-your-cooling-system-vinegar.html)
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Glad you remembered that! SB says he has a tank :thumright:
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How were the thermostats? I think the condition of them might give you a clue, along with the water pump, as to the condition of the insides of the engine. Farley I think would agree unless he peeked already at that.
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Scotty, I NEED to get a tank! List of things to do...
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Farley mentioned the thermostat orifices were very clean. The water pump outer housings were nasty, but inside not too bad.
The powerheads were pretty damn clean.
Priced new 25" shaft twins today just for reference. Bombardier E-Tec 90's, $18,500.
Yamaha 25" four-stroke 90's, Suzy 25" 4 stroke 90's....around 17K, the Suzy's just a bit less.
Merc's were too heavy in 90 horse....380 pounds for two stroke, 402 for the four stroke (each).
The way Farley built them...Lord willing they'll be two chicken' eatin' babes for a LONG time :thumright:
Sure beats buying new ones right now. Try 'splainin' THAT to the wife :shock:
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How were the thermostats? I think the condition of them might give you a clue, along with the water pump, as to the condition of the insides of the engine. Farley I think would agree unless he peeked already at that.
Hi Rick,
The powerheads were in very good shape considering the lower units. There was very little evidence of powerhead corrosion. When we took off the thermostat covers, the passages were considerably clean with a small amount of salt. The thermostats appearance wise were fine. There was very little if any salt in the exhaust tuner or powerhead base. A little corrosion on the stud nuts (brass). Very little carbon build up at the main exhaust opening. These engines didn't appear to have excessive hours, just neglect. I think these engines sat a lot. Someone had been tinkering the low speed mixture adjustment on the carbs because they were completely maladjusted too rich and too lean; I always check before tear down and compare to the base 1 1/2 turns out so the engine will start and idle reasonably. Also someone has got the timing and synchronization totally messed up. The side view of the timing arms in the photos are showing the timing at full advance against the stops with the throttle position at idle. Almost like someone had the timing arms off and the spring is in backwards. I really don't know how they ran at all. I'll be over at Bobs in the next couple of weeks to deal with that and get them fired up and adjusted.
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So should I get the plastic barrel Farley? Or will muffs do?
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I'll bring everything; muffs, fresh non eth pre-mix, tank and line,tools, etc, etc. These engines don't need the vinegar massengale treatment. I can get pretty close with adjustments on the hose and when we splash her, I'll do the final idle speed in gear before we blast off. I'd hate to see how fast you can rig a boat when your busting your ass, holy crap! It looks fantastic!
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Having fun Farley... :wink: :wink:
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Do you know the weight of these two motors? Can't wait for the sea trial!
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Want to say somewhere around 340 each with SS props, but Fitz will know exactly.
Come on over when she's ready :thumright: