If the water leak is not too bad, you could dry it off and put a bead of silicone to seal it. Those 1/4-20 bolts that typically hold the water jacket to the cylinder head like to break.
When I did the gasket on my IL6, I probably broke 10 bolts. Luckily on that motor, the block casting was...
Although I have never been able to find any proof, I believe my Garmin with built-in maps is updated over the air. I say this because the main channel in Barnegat Bay is uncharted on paper maps, as it changes all the time. However, the GPS unit always has the proper buoy positions (or nearly...
Normally the wood in seats is 1/2 plywood. However, if yours is thicker, replace with the same stuff.
I would use pressure treated plywood that has had a chance to dry well. Apply a couple of coats of oil-based varnish or polyester resin to seal it and use stainless steel staples to reattach...
Gee, can't you swap the relays and wiring from the newer motor to the old one?
Making a new wiring harness is not difficult, but the swap would be better.
Generally, the PTT motor wires should be cleaned, as well as the wires supplying power and ground to the solenoids. Don't forget to make sure the PTT motor black (ground) wire is well grounded.
I cannot comment on the boat, but I have that exact motor. It is one of the best 2 cycle motors ever made, IMO. The OMS oil injection runs at about 60::1 and allows the motor a precise mix of fuel and oil and allows good trolling and idling. It has 6 carbs or 2 three throat carbs, depending...
The Marine GPS units are priced by screen size and visual acuity. The reason is that a larger, more high def unit is easier to see the features of the waterway, making them better. Some units have world-wide built in maps, and others use downloads or plug-ins to provide the updated date to...
Changing over the motor and electrical stuff is pretty easy. That is routinely done, when buying a new PTT motor as they usually come in the two-wire version, with the relay kit and harness.
Of course, that presupposes the mechanical parts of the PTT on the older motor are still good. Also...
Generally speaking, compression testers are often inaccurate. However, they are usually reliable. If all the cylinders read the same (within 15%), the compression is good. I think your numbers are just fine, despite what the manual says. Is that a Merc Service manual?
Disconnect the ground wire and test the coil with an ohmmeter. The primary wires should have nearly a dead short. A few tenths of an ohm resistance is good. Test the spark plug wire to the ground wire. It should have some resistance and not be open, nor a dead short. Clean the points and...
Lou, NOAA has buoys all along the coasts of the oceans of the world. These measure and report wave heights, period, water temp, wind speed and other stuff. Here is link for NE coast of the US.
https://www.ndbc.noaa.gov/obs.shtml
Gee, we had 58F here in NJ. I was able to paint my boat's controls, with some help from a space heater in the garage. A good step toward spring fit-out, although a bit early.
You could also get a OB motor bracket (maybe a Jackplate) with enough clearance to allow the engine to tilt. Maybe that moves the weight back enough to make up for the loss of the 600# of the I/O engine block. You can then have a full size transom.
Side note, I traded in my 19' SeaRay 4.3 LX...
If you do the repair with JB Weld, you might grind out some alum. on the inside of the crack, and wipe before with acetone, before the repair. The outside might need some JB, to finish filling the crack, but try to minimize that, with the inside repair.
Does that boat have a self-bailing cockpit? If so, check the scupper hoses to the hull drains.
Most anchor lockers have a drain hose. You might check that.
Change the 6th word in my post from epoxy to polyurethane. You will need a 2 part paint on the boat bottom, but it does not need to be epoxy. A 2 part polyurethane like Perfection will work nicely
You will need a 2 part epoxy paint for under the waterline. You will likely want an epoxy barrier coat under the antifouling paint if you plan to use same, so find a paint that can do both if possible.
A 1 part polyurethane paint (or marine enamel) will work for topside.
Get someone you trust...
