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Here is an exhaust plate with some water passages totally loaded with salts

So I've been working on an 82 mariner I picked up for $100, and while I've been waiting for parts I decided to try and clean it up. I was told the motor was used in the salt and the oxide and salt buildup in the water passages was indicative of that. Lots of salt and oxide buildup. I wanted to...

I did but I figured without a drill press I may not get precise enough holes on the dummy plate to match up anyways. Plus I messed up the last bolt hole trying to dig out a broken extractor, not so much by drilling the hole. If I get a drill press however I will do that in the future. That would...

Welp I got all the bolts drilled and tapped. 5 in total. 4 came out real nice, I was basically able to pull the old steel threads out, which made lining up the tap super easy to finish the job. One I messed up pretty bad. I tried those EZ-outs. I'll tell ya, there's nothing "EZ-out" about those...

Just drilled and tapped one of them. Idk how but I was able to drill out the stud so close the old threads came out like a curley fry. Just tapped it and now the bolt fits. Never tried that before. I'll try to the others and see how it goes.

Well not a ton of luck on the bolt removal yet I've pushed the extractors to the limit on one already, so I'm looking at new options. Id imagine drilling and tapping is next?

Yeah they are definitely metric. I'll be sure to use the little thread testers and try to get a good match. Really wish they used beefier bolts for this. Took nothing to snap these.

Oh okay makes sense, great info. Especially on the busted bolts. The two head bolts I snapped I was thinking of running to a large hardware store near me to find replacements rather than finding OEM ones. I'll look from proper steel, as well as look for some taps or dies and aviation permanent...

What does chase the threads mean? Aviation sealant? What will that do? Will it stop the bolts from salt welding again?

Got the power head off. Broke 2/7 bolts though. They left me enough shank I think I can twist them out. This will make extracting the original bolts much easier.

Man a drill press would be sweet for this. Yeah doesn't look too tricky to pull the powerhead. Looks like the bolts run in from the bottom? Two of the snapped bolts are just too obscured by the lower cowling to leave the powerhead on.

Has anyone on here pulled the powerhead on one of these motors? I've done it to a 50 hp force but that's it.

Yes I ordered some left hand drill bits with paired extractors. I'll have to look into a thread protector though. I'm thinking pilling the power head to get better positioning on the screws on question too.

Okay okay I'll buy the gaskets......... ;)

Unfortunately they snapped pretty clean. I'll try the penetrating oil treatment while I wait for the extractors to come in the mail.

So the gaskets in question are the ones between the inner and outer exhaust covers. That whole sandwich seals in the exhaust intake and housing for the thermostat. If your solution will still work under this situation then I'll totally try that if I can't get the broken bolts out. I have 6 of...

Sorry I forgot to update this thread but the boat is idling fine now, thanks to everyone's help. May still need some final tuning and trim adjustments, but I'm also being a perfectionist.

Sweet thanks boscoe! Looks like I can even get the same busted screws. Is it worth actually buying the exhaust plate gaskets or would making some gaskets suffice? I have automotive gasket paper.

How'd it turn out? I have basically the same motor so I'd like to know in case this happens to me.