The Boat Project

[fun in dirt [Veteran Member]]

You are getting close now; good progress!

[Reserector [Veteran Member]]

More progress. I tidied up the drain, sanded the fuzz off the floor, gelcoated the floor, bilge and ski locker, installed the gimbal seal and bearing, installed the foam rope seal, and installed the gimbal housing.
I gave the gelcoat a full day to cure, but my socks would stick to it off I didn't keep moving. I now have a blue jean butt print next to the bilge where I sat to tighten the nuts.
The other problem I ran into was that the two bolts that pass through the inner casting into the gimbal casting have become "the bolts Excaliber". They were the first thing I installed, snugged them down to hold everything, then started working down the stuff nuts. Once fully seated, I went back to the bolts, and they won't go on any farther.
I loosened the inner casting to make sure it was not binding them, but no go. I can back them out one round each and then they jam. Both have one round of freedom. Where is King Arthur when you need him?
I will try to get some penetrating oil in the threads, and maybe use an impact on a light setting. I had to walk away to avoid making rash decisions.

[Reserector [Veteran Member]]

With the gimble housing in place, I moved on to the engine. I figure that if I get the heart of the boat in place, I can start bringing it all together.
As you can see, a Mercruiser 140 replaced an OMC 3.0 at some point. It was all Cobra to start with.
It was a bit of a mess. Plug wires were a mile long. Car starter. Stuff like that. Not terrible, but not exactly loved, either.
The first thing I replaced was the starter. New, marine version.

I checked compression, but the results were all over the place. I think it may have sucked some rust flakes through the valves, preventing a good seal. I put some oil in each cylinder and tried again. Looked around with a scope camera and the bores looked ok, but I was right about rust or dirt getting in there.
With oil added, some were better and some were the same. I let is set for a day and all was well. I suspect that there were stuck valves, rings, and lifters before because the later results were 150 across the board. Yay!




Shiny new starter





Then I got the dude up on an engine stand and found this:  Cracks with coolant stalactites running out of them.  Also, a missing freeze plug in the manifold, and one behind the flywheel that was popped out.
The drain petcock on the block was open, so I think the PO did not realize that it froze before he had a chance to drain it.  I know the guy, and even though he gave me the boat, he was excited to see it have a new lease on life because (he thought) the engine was in really good condition.







At first , I was bummed.  Almost defeated.  But I took a breath and started researching.  I learned that this is a common failure, and that JB Weld or MarineTex is usually adequate to repair it.
Since the engine is on a stand, and I am no stranger to casting repairs, I decided to braze the cracks as a stronger, more permanent repair.  As luck would have it, I was out buying some new brazing rods and got into a conversation with another welder who had done this same repair on his boat using special stick welding rods.  He claimed that the casting is so thin in places that he kept burning through and ended up going over it with brass.

I brazed mine, and then coated it in JB Weld just to go completely overkill.  I later found a small crack up near the head that I repaired with JB Weld only.  I did't want to heat soak that area.
My only concern now is that cracks may develop in the bores.  That would be the worst-case scenario.  I don't think that will happen in this case, but I had it happen in a small block Chevy once.  Time will tell.  I'm going to run it and hope for the best.

Cracks prepped, and preheated, with a "tack" braze in the middle of the longest one to stabilize the area.



Brazed


Covered to allow it to cool evenly


Cleaned up


JB Weld applied and smoothed with an ice cube.

[fun in dirt [Veteran Member]]

I admire your patience with this project!!!

[Brake Weight [Veteran Member]]

I admire your patience with this project!!!

This^^^. Not I.

[Reserector [Veteran Member]]

More catching up:
It's an '82 engine,  so it has the big ports on the head.   Too  bad it has a 90s manifold. 




Since my plan was to replace the old crank seals,  i took that opportunity to check clearances.   Everything looked good.   Within service limits. 






I took most everything apart and freshened it all up. Painted.   Replaced freeze plugs.   That sort of stuff. 

[Reserector [Veteran Member]]

I pressure tested the block and head.   It held 15 psi for hours,  so I'm happy about that.   Hopefully that means there are no cracks in the cylinders.   

​​​​​​​Starting to button it back up.   I got the wrong plugs.   (Long base)  
Re placed the distributor module.   Came with pigtails.  The old parts are probably good,  so I'll keep them for spares. 



Had trouble finding an affordable replacement for the original OMC fuel pump,  so I went with a Mercruiser type that has the built in filter.   I'm still going to use the OMC spin-on filter as a primary. 
It is getting treated to all new hard lines. 

[Brake Weight [Veteran Member]]

A little OCD but I like it. Would’ve done the same myself if I were doing it. LOL. Looks good.

[Reserector [Veteran Member]]

I consider a boat to be more like an airplane than a car because if you beak down, you can't get out and walk. At least you don't crash. You are, however, dead in the water.

[Brake Weight [Veteran Member]]

What is the car with the gold wheels and what is the story on the Audi? I have a small thing for euro cars. Did a timing belt and water pump on my oldest's Jetta a few days ago. Waiting on a wheel bearing and a wheel hub to get it back drivable.