1996 225 Mercury Offshore (carb)

[fitz73222]

Now back to our regularly scheduled program....Please!

[Fletch170]

SO,

Heavy 21 foot boat with a lot of V, will have 85 gallons of fuel, Ice, 300 beers, 3 guys and a whistle. 19" prop?

[fitz73222]

Should swing it no problem...

[RickK]

Now back to our regularly scheduled program....Please!

Get on 'em Farley  

[Fletch170]

Ordered the correct coupling for the pump housing and water pipe. (Fingers crossed)

In the meantime, went down to True Value hardware, and picked up two 3/8th barb brass fittings to match the 1996 3/8 thermostat out hose. Used a little Blue loctite, and shes all set.

Also picked up a 3/8 bung to close the port which was used to cool the DFI system on the optimax. Being this is a carb, it is not needed.

FRANKENMERC!!!!!!!!!

[Fletch170]

[dburr]

Boltdepot.com for hardware......

They will have what you need Christian and for nowhere near the cost. I had the same steering bushing issue you have on a 70 Merc. All The hardware that came off was not really reusable and OEM prices were crazy.  For the cost of half of what the plated OEM head bolts was, I was able to replace EVERYTING (PH, mid, lower, cowling mounts, bushing hardware, LU and shaft bearing mount and some misc stuff) with stainless.

They have just about any type fastener in any grade and shipping is fast..

Worth looking at just to compare prices, and no I don't work with/for them, I am just a cheap SOB that lives is out in the willywags with the local TrueValue ($$$) as the only close (within 30 miles) option.....

Really good progress!

[Fletch170]

Nice!!!

I'll check them out. I purchased all OEM stuff fo far for the mounts, etc, but I need a few more things. The prices for OEM stuff is INSANE, but at least I know it's correct.

[Fletch170]

The rebuild begins!!!!

[fitz73222]

Nice work Fletch,

Coming along nicely.... Love to see nice clean work.

[futch13]

Damn nice work      you need a job?????  Looking for a good tech  

[Fletch170]

Thanks Guys! I'm not a mechanic by trade, but I'm a much better mechanic than a glass and paint guy. Anyhow, a few things to point out from the build thus far, which will come in handy to anyone swapping dissimiliar year parts.

Issues are as follows:

1. Newer mercs have a 1/2 inch barb and tube (which carries seawater) heading from the t-stats to the mid section/ exhaust. Older mercs are 3/8 barb and tube. I replaced the lower barbs with 3/8 (purchased at hardware store)

2. The water pumps on the 2007 optimax, and the 1996 carb lower end are the same, however, the COUPLING that connects the cooling tube to the pump must be the correct year for the MID section.

3. THIS IS IMPORTANT!!! BEFORE ATTEMPTING TO ATTACH THE LOWER UNIT, YOU MUST DO THE FOLLOWING: the 4 studs that mount the lower to the mid fit fine, HOWER, the 5th bolt that threads from under the trim plate, into the mid, will not fit as is. The hole for the bolt is too small, and will need to be drilled out to fit the newer (and slightly bigger) bolt for the newer mid. This needs to be done before trying to mate the 2 pieces (ask me how I know), as you will need to drill from the top of the lower unit, thus not accidently drilling into the threaded portion of the Mid.

Other than that, so far so good. Also, putting the lower unit back on while the engine is not on the boat is an EPIC pain the the ass.

[Fletch170]

Some pictures with the lower cowls back on. Shes pretty clean now:) I'm cleaning up some of the wiring, cleaning connections, new plugs, and shes ready to roll. (Yes, all new t stats and rubber gaskets).

[gran398]

Beautiful work Fletch

[futch13]

Good job Fletch