Gale 5hp powerhead to Johnson 6hp body

[BigB9000]

I have a lot of extra 6hp parts left over from the restore/creation of my twin 6hp's.

3 of the engine I received had blown/seized/overheated power heads.
I had one 1963 sea king 5hp. I needed a shift handle so I borrowed it from that engine. Now I have myself a really nice 5hp powerhead, putting 70ish psi in each cylinder.

The gale had the pull start on top of the flywheel, unlike the 6hp's that had the starter looking pull start. I want to use one of my evinrude hoods on it, as the seakind hood is an ugly duckling joke.

So, the plan is to bolt the 6hp "intake manifold to plate" plate onto the 5hp thus, allowing the brackets for the starter. Then remove the gale ignition system, and replace it with the 6hp. to allow for the 6hp flywheel.

All that I believe SHOULD work. However, the 5hp's carb has 2 adjustment knobs, where the 6hp's only have one, so, carb swap too.

Will all of this work? opinions, thoughts?

Pics:

Edit; fuel pump.... 6hp too?

You may ask, what about the shift handle?! I'll use a broken on for my Frankenstein outboard. Ill probably put 2 large bolts on hood pan just to keep things interesting.

 

[1946Zephyr]

Re: Gale 5hp powerhead to Johnson 6hp body

Yea, this looks like a good job for "trial and error" so to speak. I believe the powerhead mountings are the same. I would check that closely. Do both powerheads have a thermostat? Having one needle jet screw vs. two, won't be an issue. It's when you have to drill a hole to add one, which could be a little fun. I think the toughest conversion will be the starter assembly.

 

[BigB9000]

Re: Gale 5hp powerhead to Johnson 6hp body

same mid section and same gasket. Power head will bolt on without issue.
Also, that intake manifold will bolt (or, screw) right on too.

I noticed that too about the 5hp, no thermostat;

I guess gale's were too good for a tstat.

 

[F_R]

Re: Gale 5hp powerhead to Johnson 6hp body

same mid section and same gasket. Power head will bolt on without issue.
Also, that intake manifold will bolt (or, screw) right on too.

I noticed that too about the 5hp, no thermostat;

I guess gale's were too good for a tstat.

Did you remove those intake manifolds and take a look? The manifold and reed plates are very different, as well as the ports in the crankcase where they bolt on. Will it fit on there anyway??? I don't know.

 

[1946Zephyr]

Re: Gale 5hp powerhead to Johnson 6hp body

Yea. I had a little Sea King (Gale) like that and they are quite the interesting design. Some of these Gales in the smaller hp's didn't have detachable heads, rather they had water jacket covers like the mercs. I would check that intake set up over closely though.

 

[BigB9000]

Re: Gale 5hp powerhead to Johnson 6hp body

You guys are correct. Completely different intake. The only thing this block is being converted to is a paper-weight.

 

[1946Zephyr]

Re: Gale 5hp powerhead to Johnson 6hp body

what about all the stuff on the top half? Won't that work on the 6hp leg?