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Bare metal is best, however, it will oxidize some before you can apply the epoxy. Use a fine sanding or dremel tool to clean it up. Wipe with acetone and then immediately mix and apply the marine-Tex. Some years ago, I did this repair on the inner water jacket cover of a Merc 4 cylinder OB...

Gee, a lot of folks likely do the upgrade like you. Can you get a new wiring harness for your motor with the electric fuel pump wiring?

OK, so it sounds like no water is getting into the combustion area. That does not mean that compression is not getting into the cooling passages, causing the overheat. Do your head gaskets have orings as well.

They have remote starter cables for Mercs and other motors. Mechanics use them on motors mounted on stands. You might look for them. The other choice is to make one. Find a short engine cable extension and a keyswitch and wire it up.

You can epoxy the pitted areas. If you clean the metal, wipe it with acetone and use Marine-Tex to fill the pits, it will add some time to the block.

Gee, smell the stuff. If it is gear oil, it will stink from the sulfur in it. If it is 2 cycle oil, it will smell like gas or oil.

White gelcoat usually holds up well. The darker colors are the ones that get chalky. Also, gelcoat doesn't have a clear coat over it. Maybe it is paint?

OK, let me ask a dumber question. If his motor does not have the machining for a mechanical fuel pump, why does it not have the wiring for an electric fuel pump?

A lot of times clean comes from water leaks steam cleaning the parts. i.e if one spark plug is real clean and the others are tan/brown, the clean spark plug may be getting water into the cylinder.

Let me ask a dumb question. Why do you need an electric fuel pump? They were used on late model carbs and fuel injection. They were needed on FI, but not essential on carb motors.

U joints are not expensive, but labor is. Say 2 hours of shop time plus $200 for parts. So $700. Add gimbal bearing and bellows, brings it up to $2K. Just a guess on the gimbal bearing and bellows. None of this is hard to fix for someone with a decent car repair background.

Some stuff from a Merc 150HP service manual. It covers 200XRI model. Cylinder Heads and Exhaust Divider Plate 1. Inspect internal surface of cylinder heads for possible damage (as a result of piston or foreign material striking cylinder heads). IMPORTANT: Cylinder head warpage should not...

Gee, so you would rather watch your temp gauge, than the water conditions, or the kids on the tube or what have you? Also, if the water pump fails and water stops flowing, the temp gauge likely will not show an issue. A water pressure gauge doesn't have this negative feature. The upper pump...

Unfortunately, a compression check doesn't always find head gasket leaks. However, do the compression check and maybe it will be obvious. Check the torque on the head bolts as well. Those V6 motors had a habit of the head bolts loosening up.

Gee, if you have fuel, compression and spark, maybe the spark plug wires are arcing to ground, or you are getting water in the cylinders that don't fire. That is if they are not flooded with fuel.

I would expect that motor to use a standard OB gearcase. Maybe a 1990 115HP one? It is a guess. https://www.sterndrive.cc/product/90-304-A.html

That is a marine-rated fuel pump, right?

Gee, I also think your wiring will provide power to the starter solenoid whenever the key is on. You might grab a wiring diagram from a late model MerCruiser and see how they did it. That should be avail on the web.

Compression leaks causes overheating. Are you sure the head gasket you replaced is not leaking? Did you check the head and block for flatness?

Gee, I am not sure what engine you have. Sterndrive engineering (SEI) makes gearcases for popular motors, including Johnnyrudes.