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    Broken Driveshaft

    Unfortunately I have heard of broken driveshafts on that vintage Evinrude 90HP engines. No gearbox damage, they just snapped. I assumed it was a design flaw.......
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    Two Layers of 3/4 CSM versus One Layer of 1.5 CSM

    I would recommend the cloth go over the CSM, for areas that will show, or skip the CSM entirely. CSM can easily develop bumps, compared to cloth. CSM is fine under carpet, as the bumps will not show. Overlap your seams for strength. You can fill and smooth them later. You don't need to...
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    Metal shavings in reed block

    Reed valves are pretty robust. Inspect them and see if they are cracked or broken. If not, they are fine. Metal shavings in the crankcase are not good. You have piston damage, and possibly bearing damage.
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    Starter Motor Completely Dead

    Can you test the windings with an ohmmeter? That will tell you if they are open. Also, if the solenoid doesn't click, it is either bad (not likely) or not connected correctly. Is it connected to the neutral safety switch? A permanent magnet starter will spin backwards, if the magnet is...
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    Two Layers of 3/4 CSM versus One Layer of 1.5 CSM

    The binder in CSM is not dissolved by polyester resin. I have heard that it is dissolved by epoxy resin. Mix the polyester resin light on the catalyst, so you have extra time. A short nap roller works to get the resin worked into the cloth. Fibers of the mat will move around, somewhat, so...
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    Gas Tank on Spitfire 115 TideCraft

    Pull the tank out, remove the sender and dump it.
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    MERCURY CONTROL BOXES

    They did change color, about the time of your motor. Choke went from grey to yellow/black, and charge/tach wire went from brown to grey. Gee, I think that is correct. You might check. In the early 80's, they tried to standardize the wiring colors. Some years were the old colors, some were...
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    Johnson V4AL-14 not pumping Cooling Water

    I am guessing that is an early V4 motor. Say early 60's. If she spits out the hole in the rear of the motor, after a while, the thermostat is working. It should read about 143* F. There is no telltale. I have seen water out that hole in the extension, but never understood it's purpose...
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    Any lasting proven method of painting a prop ??

    Gee, I had my Mercruiser in the NaCl for a decade. The prop never had a buildup I never used A-F paint on the prop. Barnacles would build up, a bit, when I didn't use it. There were a couple of barnacles in the "corner" of the blades, at the end of the year. I did not think they were too...
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    MERCURY CONTROL BOXES

    If the 8 pin plug fits, it should work, I would think.
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    Any lasting proven method of painting a prop ??

    Use the boat more, and you will not need AF paint on the prop.
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    MERCURY CONTROL BOXES

    That three prong spade connector looks to fit the external PTT pump/reservoir used on the early PTT equipped motors. I do not know the last year those were used, maybe mid-80s? After that they went to bullet connectors for the PTT systems installed between the transom clamps. I presume...
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    Steering system .Order new cables or new system.

    Most smaller boats (<30ft) will benefit from trimming to get optimum speed or economy. For standard performance boats, setting the trim tab so steering is easy at usual trim level is the way to go, IMHO. She will pull right a bit when trimmed down, but as soon as you get on plane, hit the trim...
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    Any lasting proven method of painting a prop ??

    Sure, sand the prop, wipe with turpentine, immediately apply etching spray primer (available in rustolium rattle can) and gloss black spray paint. Now don't hit bottom and the paint will stay on.
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    MERCURY CONTROL BOXES

    The bullet connectors are standard on my '93 Merc. I expect the spade connectors are a "modification". I would replace the spade connectors with bullet connectors.
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    Steering system .Order new cables or new system.

    Trimming and trim tabs also cancel out steering torque.
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    2005 115 Johnson PLSOR dies off idle

    New jets and the bowl plugs do not usually come with the new bowls or carb kits. usually you get gaskets and inlet needles and seat. Sometimes floats. However, if you did not swap the main jets over to the new bowls, the motor would run real rich. Your carbs may have an intermediate...
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    Steering system .Order new cables or new system.

    Gee, go with the correct length (Merc) motor on the aquasport. If it feels squirrely with the single cable NFB system, you can consider hydraulic, I think it will be fine, however. My neighbor has a twin 225HP Outrage. He was going 50+MPH, and needed to turn his hydraulic steering wheel...
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    Gel coat vs Epoxy paint

    High end yachts are painted with 2 part polyurethane paint. Awlgrip and Imron are two of those. They give superior shine, but are expensive and hard for us amateurs to apply. One part polyurethane paints are very shiny and durable, nearly as durable as gelcoat, but much better finish. They...
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    Alarm on 150 2 stroke outboard

    Is that an old Merc/Mariner? Most overheat alarms work by grounding the signal wire to the block. These wires are usually brown or brown/white. If the insulation falls off, then can short to ground tripping the alarm.
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