1150 overhaul parts list....

Clams Canino

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Re: 1150 overhaul parts list....

If you look at what we've both typed with a forensic eye, we're not coming off in much dissagreement at all when you go down the flow chart. :D <br /><br />What does stand out to me was that the guy in your example paid $1700 for a four (lets translate that to $2000 for a six) and that the hinge pin of your example was that the mechanic that did that job was too incompetant to know the difference between water damage and detonation damage on the affected piston. It does not speak to cylinder walls and hones. It's also alarming that a "proper rebuild" on an inline four outta cost $2500 (when you combine the 1700 and the 800). This speaks back to that other thread I started about dealerships and the value of an overhaul vs the net worth of the outboard - and the mess that whole topic ensues. But the bottom line is, the home mechanic needs a better way to keep one of these old beasts afloat than to throw $2500 to $3000 at it in the case of a six.<br /><br />We both agree that if you have the beans you're better off taking all 6 .015 over and starting new. And you'll see no argument from me on the value of inspecting the exhaust dividers, particularly if salt water was ever involved. And the bearings are too cheap *not* to replace while you're in there.<br /><br />As for the rod bolts, Type-I is meant to be re-used, Type II is not. (per the manual)<br /><br />The rest of this discussion is about probability theory and risk vs reward asessment. We need to always look at both sides of that equation when giving advice or else the only people who could "afford to boat" would be the ones the dealers and shops annointed with enough spending cash to go 1st class all the time.<br /><br />Informed people working outside the confines of repair shops and warantee issues - face those choices. And as soon as you start compromising on cash, there are many questions that come into play, overall crank wear being the 1st variable you put into the equation of "how far to go" vs "how long will it last". The next variables are "is it a boost port engine?" and "what is it's intended use?" <br /><br />And remember, I come from a long careeer in New England where fresh water lakes abound , but the "sweet spot" for boating is a lousy 10 weeks long. Fixing it by "next weekend" or in a few cases "tomorrow afternoon" was the prime criteria set down. Several times I've gotten the "all it has to do is finish out the season" line.<br /><br />-W
 

Clams Canino

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Re: 1150 overhaul parts list....

Rodbolt.... you cursed me! the exact "worst case scenario" we were discussing swam up and bit me in the ***. :D <br /><br />The job that came in over the past weekend reads as follows: <br /><br />1988 115, presented as a classic #3 meltdown by the compression guage. Gave the customer a rough estimate with the usual bit about "finding more when we open it up".<br /><br />I open it up and find that there was an engine wide overheat. #3 is as melted as I've ever seen one, the rod bolts had somehow stretched loose and had he not shut it down fast I'm sure it would have broken very soon, But the #3 rod is toast. #1 and #5 somehow escaped damage. #2, #4, and #6 all had some pretty bad skirt scoring. Some crank journals and big rod needles are blued but measure OK.<br /><br />So I call him back and reccomend we just take the whole damn thing .015 over and start from new. No dice... "too old to sink all that in" etc etc.<br /><br />So.... we go to plan B. #3 goes .015 over, new piston, good used rod. The rest get honed as there was no cylinder wall damage above the ports, wear and out of round within spec. Some stray aluminum gets removed from the walls with muriatic acid. #6 gets replaced with a good used piston. #4 which has the least skirt damage (and is fine in the top 1/2)goes back in. Being a low dome motor, #2 gets replaced with a high dome with deflector damage that I pulled out of something last year. 10 minutes wtih a bench grinder, a good file and a bit of sand-paper and it's suddenly a low-dome with *no* damage. :D In she goes. New rings all around, new rod bolts.<br /><br />Now to keep the cost within 110% of the estimate things that are a little blue but otherwise measure OK get allowed to live to fight another day. We now refer to the blueing as "heat-treating". :D The planned carb rebuild turns into a quick carb cleaning. The lower ball bearing is replaced, the upper passes the sound and wiggle test and skips what would have been a routine replacement because it has no play in it at all.<br /><br />And another inline lives to fight the good fight. Not the way I wanted it to... but still pretty darn "OK" overall. I'm comfortable giving it a 90 day warantee against catastrophic failure or compression loss so long as "the rules" are followed. I'm sure it'll live on for many more seasons so long as it's broken in gently and not demon raced. Should it die again a few years down the road, there's still plenty of cylinder walls to bore it all out "next time".<br /><br />Is it the way I wanted it. Not really. Am I comfortable sending it back to the lake for some more bass fishing, sure.<br /><br />Sometimes it's not how you play the game, it's if you win or lose. Having a deep inventory of used parts helps, but so does being willing to go to "Plan B", when "Plan A" would result in another Tower of Power leaving the lakes forever.<br /><br />Now... It's time to dress it back up and give it a quick water test. Wish me (and it) the best of luck. May the fish remain nervous.....<br /><br />-W
 

jheron

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Jul 21, 2004
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Re: 1150 overhaul parts list....

Hey guys thanks much for your replys :) Sorry for the delay but I have way to much on the go rite now :eek: know what I mean? lol<br /><br />I am using a telescopic guage with a vernier calliper for my measurements, here are the results:<br />
Code:
1. avg = 2.8738  2. avg = 2.8734  3. avg = 2.8729<br />   max = 2.8750     max = 2.8750     max = 2.8745<br />   min = 2.8725     min = 2.8710     max = 2.8715<br /><br />4. avg = 2.8738  5. avg = 2.8871  6. avg = 2.8734 <br />   max = 2.8750     max = 2.8890     max = 2.8765<br />   min = 2.8730     min = 2.8850     min = 2.8710
Give or take a thou :p <br />Well it looks like #5 has already had some work.<br />I think my best bet is to rebore the hole block. I got a couple of prices on boring them .015" over and the best I could find for doing a blind hole is C$65.00 a jug. Is that reasonable?<br /><br />As for my intention for this motor? Well this will be going on my first boat with a helm (there are some posts by me on the rebuild of the boat on here too)and I plan on doing lots of water skiing, fishen and cruisen :cool: So I want a reliable motor and who wouldn't eh? :) <br /><br />Thanks for all your help fellas!<br />sincerely Jon
 

Clams Canino

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Re: 1150 overhaul parts list....

Some machine shops charge X for the 1st one for "set up" and then 1/2 X for the other 5. If you find one of those all the better.<br /><br />-W
 

rodbolt

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Sep 1, 2003
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Re: 1150 overhaul parts list....

clams<br /> I am with ya.<br /> in the past I have done some repairs that now I may not. my clientele is a bit different. on that repair,his option not to fix it, I would only warrenty that it was assembled properly. any other failure is his. but having somany crabbers and such here that go to the same church, kids all went to school together plus I am related to 1/2 of them, I have been known to short cut things toget them back on the water with a caveat, they sign a workorder stating that its a temporary patch not a rebuild and no warrenty for parts failurs. some of my patches have had over 10K gallons of gas run through them. if its blue but still in spec and not scared I have been known toreuse them. cause sometimes the man just plain aint got the cash and 400 pots in the water and has to go. other times I act asa bankand fix it then get paid all summer long.<br /> with a low dome motor and reduced timing it should live. a high dome running all factoiry specs may not. good luck with it :)
 

briannh1234

Petty Officer 1st Class
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May 19, 2003
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233
Re: 1150 overhaul parts list....

jheron -<br /><br />I paid $50 a hole at an automotive machine shop.<br /><br />- Brian
 

jheron

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Re: 1150 overhaul parts list....

Thanks Brian :) <br />By the way guys I am learning c++ programming and for practice I wrote a tiny application that gathers your bore measurements and calculates the average bore size, max and min and also calcs the diff between max and min down to 5 decimal places. It works very well and is faster than doing it on a calculator the app is only 520kb and will run in windows or dos. If any body is intrested let me know and I will email it to ya :) <br />regards Jon
 

Clams Canino

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Re: 1150 overhaul parts list....

Hi Rodbolt, regardless of condition, I warrent all overhauls / rebuilds for 90 days against catastrophic failure. This does not cover melted pistons (which are *only* caused by some form of abuse of the operating paramaters. What it does cover is gaskets and seals, rod and rod-bolt failures, any bearing failures, compression loss from other than melting a piston, etc etc. <br /><br />Since I only put in good used parts to shave the bill, I'm OK with giving it my normal coverage. Up north 90 days WAS the whole season, and I don't like to cover winterizing issues beyond my controll - thus the 90 was born.<br /><br />I test ran the motor today and all looks and sounds well. The owner comes tomorrow and we are prolly gonna go out on the lake for a quick cruise to get the idle needles dialed in 100%. It's got over 1/2 hour on the muffs, so I'm OK with taking it to 4000 for some cruise testing.<br /><br />Now, next weeks job is really intersting. An Army feller just back from Iraq on extended leave, his boat was in the shop for EIGHT MONTHS (#1 meltdown) and they **still** didn't get to his Tower. The shop had excuses "parts availability yada yada. BS<br /><br />He called me with his tale of woe.... I told him to be here at 0800 Tuesday morning, be prepared to spend the night, and he'll be out of here by dinner on Weds with it done. I'll report back on how this all went, but I'm not scared. :D <br /><br />I figgure if this feller spent the better part of a year risking his neck over there in hell, I can find TWO days to see that he gets on the water ASAP. I put my machinist on notice that we may have to do a block "on the fly" Tuesday afternoon.<br /><br />OK - I'm off on a three day weekend.... Ciao!<br /><br />-W
 

dodl

Seaman Apprentice
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Nov 9, 2003
Messages
49
Re: 1150 overhaul parts list....

Hello,<br /><br />Clams, what do you mean with a "sound and wiggle test" at the main bearings?<br />And you really reused the needles of the rod bearings?<br /><br />I am currently rebuilding my old Merc 500 and i'm also at Plan B now :) <br />Replacement parts are too expensive here to do it right. On the other side, i'd like to use the engine this year, and if possible next season too.<br /><br />Now i have 4 good used pistons, new rings, do the Cylinder walls with a 3" Flexhone. The engine had 3 scored pistons due to overheating, but nothing is blue...<br />I'd also like to reuse the bearings. Needles look perfect, but have to measure them. Didn't know how to test the main bearings though...<br /><br />thanks a lot<br />martin
 

Clams Canino

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Re: 1150 overhaul parts list....

If the main ball bearings on the ends of the crank spin pretty silently and have no perceptable or measurable wiggle - I let them live.<br /><br />Rod bearings for 99ci measure .056 - or not. That's what decides.<br /><br />-W
 

jheron

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Re: 1150 overhaul parts list....

Here is an update on my project :) <br />Block is in the shop now getting all six bored 15 thou over and ALL new needles and ball bearings are waiting to be installed along with the 6 new low dome pistons and rings ect... :) <br />Man I cant wait!! She will be fresh that's for sure :) <br />By the way how about some tricks for re-assembling all those needle bearings? Me thinks I will need a good scotch or 3 to muster up the patience ;) <br />Jon<br />P.S. Hey dodl I bet I know where you can get a good deal on the parts you need I can't tell you here so give me your email and I will send you the guys contact info ;)
 

rodbolt

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Sep 1, 2003
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Re: 1150 overhaul parts list....

jheron<br /> use needle bearing assy lube. in a pinch vasoline works as well. never use a magnet to pick up loose needle no matter how tempting.<br /> make sure you check all the other engine subsystems as well. dont want to pop another piston.
 

Clams Canino

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Re: 1150 overhaul parts list....

Ummm..... why not a magnet? Once in a while I fumble one of the 16 in. The ONLY way to get it is with a magnet. <br /><br />-W
 

dodl

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Nov 9, 2003
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Re: 1150 overhaul parts list....

Hello,<br /><br />Thanks for all advice...<br />I found out, dougrussel does international orders.<br />Now that's good news. Since prices are only 30-50% of ours, i will order new bearings too. It's unbelievable. The gasket set alone...<br />About 50$ at dougrussel. Over here, the best offer was 180$.<br /><br />I checked everything else and the engine looks good for a 30 year old saltwater Outboard. Of course i broke 2 screws at the cylinder block cover. ;) <br />I don't think i will pop another piston. The reason was the impeller, that's why the engine overheated. The funny thing is, the engine ran really good after i fixed the impeller, regardless of the scored pistons and some stuck rings.<br /><br />@jheron: my email is martin.heller@chello.at<br /><br />many thanks<br />martin
 

jheron

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Re: 1150 overhaul parts list....

Update...<br /> Well I must have gained some patience in my old age! She went together way slicker than I figured, hell I didn't even need a scotch... but I had one any ways :p <br /> I will go into detail here in the hopes it will help out some one else.<br />First I changed the crank upper and lower bearings , I set the crank in the deep freeze for a couple of hours and put the bearings in the oven at about 175F. I set up a jig to hold the crank so I could pound the bearings on without stressing out the crank but they just slid on by hand like nothing! I then set the crank in the oven at about 120F to dry up all the condensation from being frozen and that was that done.<br /> Then I assembled all the pistons and rods together I used OMC needle bearing assembly grease and it was a snap I kept the wrist pins in the fridge and they just pushed in by hand :) <br /> Now for the rings. I had a standard ring compressor but I discovered that I could not get it in there. So I cut the top and bottom off of a regular beer can, applied lots of oil to it and wrapped it around the piston, there is a gap of about 3/4" in the edges of the beer can that work great to make sure your endgaps line up proper for the index pin on the piston. For the ring with the endgap on the opposite side I just marked the ring inline with the other 2 so I could tell it was lined up from the gap. I then just slapped a tyrap around it and held it over the bore and it practically fell in! All six went in with no broken rings :D And the beer can actually broke in and was even easier to use towards the end!<br /> The main needles and reeds went on with no trouble. I had a friend help me set the crank in place then I stuck a bolt in each end cap to hold it in place while I attached the rods, these needles where also a piece of cake! I did drop a rodbolt nut into a piston but my handy magnet quickly retrieved it :) <br />So that's where I am now the worst is over! Today I am going to torque and locktite the rodbolts, I have a nice mastercraft 'pro' 7/16" wrench that has no trouble getting on the rodbolt and it so happens that a 7/16" will grab on the 3/8" drive on my torque wrench. so to set the torque for 15'lbs. I clamped one torque wrench to the bench(deflector style) and put the closed end of the 7/16" on it (same end that will go on the nut) inline with the handle then took my other "clicking" torque wrench and adjusted it till it clicked out when the other one reached 15'lbs.<br />With a 7" wrench it worked out to about 130"lbs.<br />It seems as though they could be tighter but that's what the book calls for? Does my method make sense? :rolleyes: <br /> I got some permetex aviation for the case halve and some ultra black for all the water jacket gaskets. The book talks about greasing the gaskets what's the consensus on this one, grease or just use permetex?<br /> Also do I need to worry about the needle assembly lube should I try to wash it out and replace with tcw3 or will it just run out in due time without any problems with lubrication?<br /> Well thanks for any input and sorry about my poor grammar! :p <br />sincerely Jon
 

Clams Canino

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Re: 1150 overhaul parts list....

Originally posted by jheron:<br /> With a 7" wrench it worked out to about 130"lbs.<br />It seems as though they could be tighter but that's what the book calls for? Does my method make sense? :rolleyes: <br /> I got some permetex aviation for the case halve and some ultra black for all the water jacket gaskets. The book talks about greasing the gaskets what's the consensus on this one, grease or just use permetex?<br /> Also do I need to worry about the needle assembly lube should I try to wash it out and replace with tcw3 or will it just run out in due time without any problems with lubrication?<br /> Well thanks for any input and sorry about my poor grammar! :p <br />sincerely Jon
True rod bolt torque is 180, as long as you can simulate that with a Micky-rig - you're OK.<br /><br />LIGHT black silicone goop on the water jacket plates. Red if you did the innermost plate around the exhaust ports themselves. Case halves should be anything that will not shim the halves, I use Yammabond 4.<br /><br />-W
 

jheron

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Jul 21, 2004
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Re: 1150 overhaul parts list....

Thanks Clams!<br /> "LIGHT black silicone" Does that mean that my ULTRA black is no good? <br />I guess there is no problem with the assembly lube either?<br />Thanks again Jon
 

Clams Canino

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Re: 1150 overhaul parts list....

I meant to use it light as in THIN. You don't want it to squeeze out and block water holes. <br /><br />-W
 

jheron

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Jul 21, 2004
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Re: 1150 overhaul parts list....

Thanks man :) <br />I just bolted on the case and I can't find any torque spec's for the 3/8" bolt's that go into the center main bearing carriers? These are the 2 bolts with the tin keeper washers on them.<br />Jon
 

rodbolt

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Re: 1150 overhaul parts list....

leave the silicone in the trash around any exhaust ports, the fuel/oil present in the exaust will eat up the silly cone, use perfect seal.<br /> thats what its made for.<br /> Clams<br /> the reason NOT to use a magnet is it will magnetize the needle. if you get two with same polarity they will stick together and not roll.<br />once magnetized there is no good way to demagnetize the needles. will it fail everytime? probably not. but one failure is one to many.<br /> there are to many things that can and usually do go wrong without me adding to the list.<br /><br /> sillycone has no place in the outboard industry except maybe the 60* jonnyrudes and they dont last long in saltwater anyway.<br /> I see failures momthly that were caused by improper sealants.<br />fresh water guys may get away with it for a bit longer but not here.<br />a 2 hour run each way at 5000 RPM is the norm not the exception.<br /> any weakness will be found rapidly.
 
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