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Thanks Shoestring, I was hoping this thread would encourage more to restore these cool old boats! If you truly believe in it- that's half the work.

Transom mush removal. Pretty much just pulled it apart by hand, was at about a burly 0% structural integrity I estimated. The last of the 6 legged stowaways perished in the soapy bilge mulch swill. Still need to unbolt outdrive collar? portal? (not sure what it is called) so last of wood can be...

Update: Replacement crane boom completed. This one is 12' instead of the Catalina's 10' 6", and solid, 7018 welded, steel. 😎 Lifted and moved Mercruiser no problem so should be safer than the last one that nearly failed. Great success lol

Didn't know Durabak was Navy grade! That's very reassuring and looks like it came out great, sound deadening is definitely a plus. Is that stuff expensive compared to other options? I need to affordably seal a bunch of plywood decking soon.

That's a good idea, check those coils! On my 4hp they were pretty crusty because that motor has a pretty open cowl at bottom and can get splashes all the way up to flywheel. I wire brushed and greased mine and saved em just in time. That rust can definitely screw things up!

A few more ideas: If fuel pump just rebuilt may be worth checking it for flow, I like to put a clear fuel filter on right after pump to "see" it working consistently at various rpm ranges. If a check valve in diaphragm pump is stuck or not sealing well it may only pump at higher speeds. This...

Oh wow, she does look nice and clean under the cover! Love finding old engines that were actually cared for. Personally, I like my cheaper older engines that I can fix and take care of myself. Nothing wrong with that! A little care getting her ready for the season and you should be good! And...

I'm no expert but that sounds like maybe dirty reed valves to me. Maybe some dirt got in when working on it? With carb off might want to try blasting the reeds with carb cleaner, ether, or some other thing that dissolves varnish/gunk. Was it running normally anytime recently? Do you have...

I have a very similar 40 hp motor. Think mine is a Mercury model "402" which I think means 40hp / 2 cylinder. In any case it looks very similar. Mine ran great until I eventually broke the seemingly fragile pull start housing (hopefully you have electric start!) but as far as I know this era and...

Does that year model still have the rich/lean adjustment? Check that to see if it is way out of spec. If you don't know the proper adjustment I'd start at 1.5 turns out from closed and adjust from there. Check tank vent too. My '79 Evinrude 4hp tank vent didn't breathe properly and tank would...

Test run with fresh oil and filter. Leaky freeze plugs aplenty!

Thanks, I am really excited to get her back together and start doing some of the more fun things like the interior and cockpit customizations. Definitely have a vision for the old girl!

Motor out, transom area nice and open finally.

Thanks, they're a great pair. I just need a mullet now! 😅

For better access to replace transom, engine needed to be pulled, so a crane of sorts was in order. Used an old Catalina 27 sailboat boom to lift the Mercruiser V8 out. Nearly failed but the makeshift setup held. This was the mock-up setup and the somewhat reinforced setup that was whipped up quick.

Digging out and removing all the crap.

Lot's of clean up. Over a dozen contractor bags of old styro mixed with leaves and mulched plywood.

Got her home finally.

2nd visit, this time to remove axles to be refurbished at home and brought back.

Looking forward to seeing more of this great old boat! Those Express models are so cool looking with all that superstructure and the open, walk around cabin design.