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  1. tpenfield

    Mercury 7.5 HP Motor Refresh (1969 model year)

    It seems like nothing goes back together the way it came apart . . . As I secure the top bearing carrier to the crankcase, the crankshaft binds up. If I loosen the 4 bolts holding the carrier about 1/4-1/2 turn, the crankshaft loosens up nicely. So, I'm thinking that with the new 204...
  2. tpenfield

    Mercury 7.5 HP Motor Refresh (1969 model year)

    I did it !!! :D :D :D :clap2: Once I saw the pins in the piston groves, I was able to line up the rings and get them to close up. It just so happens that on the other piston, I was positioning the rings in about the right place, so it must have been a matter of chance that they would be...
  3. tpenfield

    Mercury 7.5 HP Motor Refresh (1969 model year)

    I have begun putting the powerhead back together. I honed the cylinders to get rid of the glaze on the cylinder walls and have got all of the old gasket material off of the mating surfaces (no easy task). I put the new rings on the pistons and pressed the bearings into the upper carrier, etc...
  4. tpenfield

    O'Day Mariner Sailboat Restoration

    I got the boat put back on the trailer and put the rig out in my yard. I'll have to get a tarp for when the weather sets in. I tried to separate the hull & deck along more of the stern rubrail. It looks like the boat will come apart fairly easily . . . no super duty adhesive holding the...
  5. tpenfield

    O'Day Mariner Sailboat Restoration

    UPDATE: It has been a while since I have done much with the sailboat restoration. So, today I decided to flip the boat back over and begin working on the upper hull and deck sections. I hooked up the straps that I used to flip the boat originally, but this time made sure I had the boat plenty...
  6. tpenfield

    Mercury 7.5 HP Motor Refresh (1969 model year)

    Quick Update - Salt/calcium cleaning I got some salt eliminator to clean out the water jackets and side panel of the powerhead, while the engine is apart. One area in particular was the 'Flush' tube and plug fitting. I had not been able to remove the Flush Plug since I have owned the engine...
  7. tpenfield

    Boston Whaler 17' Montauk for offshore?

    This is what we call Boston Whaler days . . . and there is a reason for that. The 13 and 17 foot Whalers will not take much of a chop. 2 feet is probably the most for the 17. The boat will be fine, the captain and crew will wish they had a bigger boat. The newer designs are a bit better...
  8. tpenfield

    Mercury 7.5 HP Motor Refresh (1969 model year)

    I have received most of the parts for rebuilding the powerhead. . . I just need some flange gasket maker and maybe a few other pieces of hardware. Some of these parts look like NOS, based on their packaging, etc. . . . other parts look fairly recent. I ordered some 18-8 stainless (304)...
  9. tpenfield

    Got an IR Camera . . .

    OK,I figured out how to display the temperature . . . there is a 'bulls eye' that you can activate. then the temperature within the cross hairs is shown Here is the kitchen. . . oven is on. The counter top is at 70.7 F degrees. I put my hand of the cabinet for about 1 second. . . then...
  10. tpenfield

    Got an IR Camera . . .

    My Birthday is a couple days away, but we celebrated this weekend ( keep those card and well wishes coming :D ) I usually don't really ask for anything in particular, but this year I mentioned the FLIR ONE IR camera for IOS. . . and so it was. :thumb: I figured that I could put it to good use...
  11. tpenfield

    Mercury 7.5 HP Motor Refresh (1969 model year)

    Well I gave up on trying to pull the swivel pin out of the saddle casting, figuring if I continued trying that I would do more harm than good. So, I just drilled into the bottom of the swivel bracket until I hit the swivel pin and then threaded for the grease fitting. The area where I drilled...
  12. tpenfield

    Mercury 7.5 HP Motor Refresh (1969 model year)

    There is one other dis-assembly thing that I was hoping to take care of . . . The saddle/swivel assembly. It would be nice to get that thing to come apart. My understanding is that the swivel pin/shaft which creates the axis point between the saddle and the swivel/clamp assembly needs to come...
  13. tpenfield

    Trailer Refurbishment . . .

    Project Update: I have been slowly chipping away at replacing the wobble rollers on the trailer and finished off today. In total, I replaced the 16 wobble rollers, the 2 bow stop rollers, . . all with the non-marking kind. Replaced the tires and added a share tire/wheel. I managed to...
  14. tpenfield

    Mercury 7.5 HP Motor Refresh (1969 model year)

    I got the remains of the old key out . . . finally. :rolleyes: I got some Dremel cutting wheels and made a grinding stone about the width of the key slot and ground down the remains of the key until it finally gave up and I could chip it out. The Dremel wheel was a bit bigger than needed...
  15. tpenfield

    Mercury 7.5 HP Motor Refresh (1969 model year)

    Quick Update: I have drilled several holes in the 'woodruff' (?) key . . . still not budging. I did not want to drill too deep, but have been trying to get to the bottom of the key slot. I did figure that since it is the same key for both slots (according to the parts list) and the shaft...
  16. tpenfield

    Mercury 7.5 HP Motor Refresh (1969 model year)

    Quick Update: I got the bearings out of the upper retainer . . . racerone the heat idea did the trick nicely :thumb: Then, I pressed the needle bearing out. The Needle is a Torrington J1210, of course Torrington Bearing is no more - became part of Timken Bearing. I am having 1 challenge...
  17. tpenfield

    Closed Cooling System on Port Engine Running Hot(ter)

    I think it was Rick who said it was bound to be something simple . . . . . . and here it is. I showed it to the Admiral and she just said . . . "that little thing caused all those problems ??? " Yup :rolleyes:
  18. tpenfield

    Closed Cooling System on Port Engine Running Hot(ter)

    Sure do . . . :rolleyes: :D So I ran the engines up to temperature . . . took about 20 minutes to come up to temperature and stay steady Here is where the Port engine ended up Here is where the Starboard engine ended up. Keep in mind that the Starboard engine has 2 small holes in the...
  19. tpenfield

    Closed Cooling System on Port Engine Running Hot(ter)

    UPDATE: I found something when I took the outdrive off . . . That turned out to be a sea shell that apparently grew inside the outdrive water duct and then dislodged and got stuck that the fitting for the intake tube. Not 100% sure this was the source of that problem, but it does fit the...
  20. tpenfield

    Mercury 7.5 HP Motor Refresh (1969 model year)

    Quick Update: I have been compiling a parts list and suppliers for the parts needed to rebuild the powerhead. I inspected the lower bearing . . . it has markings of "6204" on it, which equates to the 204 bearing family. A fairly common bearing as it seems to be widely used. The parts diagram...
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