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    Polyester resin over floatation foam

    I have always heard that polyester resin will generally melt foam, except for certain kinds of foam. I think you should try a sample. Epoxy resin will not melt foam.
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    Outboard in the Lake

    Freshwater is not hard on motors, at least compared to salt water. Also, the legacy of 2 cycle oil tends to protect them from fresh water for a while. You do need to get it running PDQ. Check for spark and clean the carb. I expect the engine to have magneto ign, so clean the points and check...
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    1988 Bayliner Restore or Replace

    Gee, that 1990 SeaRay is priced about double what I would expect. It should be in the "any old boat is worth at least $2500" category. I had a 19' 1988 SeaRay Sorrento. It had quality control issues. Some parts of the boat were very well built, other parts were poorly built. The hull even...
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    Prop Locking Question (Reverse Locking Cam?)

    KJM, Those are the attachment points for the shift and throttle linkages. He needs to make sure the gearcase shifts, before he installs the shift cable on that post. The design of the throttle arm assures it is in the way of any manual "exercise" of the shift mechanism, hence, it needs to be...
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    Prop Locking Question (Reverse Locking Cam?)

    The gearcase should not "stick" in any gear, especially reverse. I would drain the gearcase oil and refill with the correct stuff. Any marine gear oil for mechanical shift motors will work. Wallyworld usually carries it. Failing that a marine store will have some. You will need about a...
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    NO SPARK 1988 mercury 100HP outboard Sea Ray seville

    Go to the crowleymarine site and punch in your serial number. It should give you an exact parts list.
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    Prop Locking Question (Reverse Locking Cam?)

    When was the last time you changed the gear oil? The shifting mechanisms do not usually lock up as you describe. Dropping the gearcase will not expose any shifting cams.
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    Broken Skeg

    I have not priced out a new gearcase housing, but the work involved is swapping the internals plus the special tools and know-how necessary will make it difficult. At least price out a new gearcase from SEI. Mercruiser used to rebuild outdrives for $2K. At that time SEI sold new ones for...
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    1995 Skeeter ss140 - 135 Mercury Black Max G179207 Constant Alarm

    That year motor had oil injection. I would suspect alarm is from that, if it is not from overheat.
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    1972 Mercury 402 - r/r water pump impeller shredded

    Check under the wearplate for impeller bits. Try to reassemble old impeller with the bits, so you can see how much is still missing. You could try a backflush, via the thermostat opening, with the gearcase still removed. Run the motor in a barrel of water, gearcase installed, with a rebuilt...
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    Fuel pump diaphram

    Sure, remove old fuel filter. Toss in trash. Install new fuel filter.
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    1993 mercury 175hp carb

    Firstly, I doubt that motor has a mercury switch that kills the ign, if she trims too far. The design of the PTT units does not allow over trim. If she runs warm, it is time to fix that. When was last time waterpump was rebuilt? Thermostats changed? Poppit valve inspected? If I understand...
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    Outboard loses prime, unless I stand the tank on end

    Sometimes the fuel pickup tubes get a hole in them. When the fuel level gets below that hole, they suck air. Of course, it could be your "run of the mill" air leak in the fuel line.
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    Need help with identifying motor

    Smell the dripped oil. If it smells like gasoline or oil, it is fuel. If it stinks like rotten eggs, it is gearoil.
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    NO SPARK 1988 mercury 100HP outboard Sea Ray seville

    Check out maxrules for a wiring diagram. Pick a diagram for a motor close in year and with the same number of cylinders. Anything after 1980 should be close. That motor will have ADI ignition. That is the flywheel spins generating voltage in the stator. This voltage is fed to the switchbox...
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    Broken Skeg

    Mercury used to sell replacement skegs. The old one was trimmed and the new one cut to fit, and welded onto the gearcase. A little marine putty to fill in the weld marks, some primer and black paint, and it will be good as new. If you pick a good welder, you do can leave the gearcase full of...
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    Fuel pump diaphram

    Sounds like a fuel restriction. It could be a clogged fuel filter, clogged fuel line antisiphon valve, clogged fuel tank vent, clogged fuel pickup screen, or something wrong with the fuel line or fittings leaking air. Merc back drag carbs often have a screen in the fuel elbow that feeds the...
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    Steering issue

    I suspect the steering actuator. You might repost in the V P I/O forum.
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    How to install a hull lift point?

    Usually, if the boat is off the ground a bit, as your garage boat cart should have it, you can simply winch the trailer under it. Disconnect the trailer from the vehicle, hook up the winch strap and crank the trailer under the boat. If it won't work, remove the wheels from the trailer to lower...
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    XR 4 Hydrofoil

    I think those whale tails are a bad idea. Adjustible Trim Tabs are the way to go. A 25 footer with a 5.0L Mercruiser will likely drag it's butt when trying to plane. The trim tabs can be put down for holeshot, and up for cruising.
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