scumfrogmillionaire
Seaman Apprentice
- Joined
- May 3, 2018
- Messages
- 32
First post here and am looking for your help. Stick with me here:
Wondering if anybody has any ideas or am I just screwed!?
My 20 hp Mercury outboard wasn’t spitting watter so I replaced the impeller and seals on the lower unit. Everything went smoothly. Now let’s rewind a little bit; Before my parts came for the impeller replacement, I decided to check the thermostat. Only 2 bolts on the thermostat cover, what’s the big deal. BIGGEST MISTAKE EVER!!!!! This one decision has led me to hours and hours of scratching my head, cursing, and most likely paying $$$$$$ for repairs. Both of the bolts sheared right away. The bolts sheared so far down, I had to take the water jacket cover off to see them. This is the part I wish I could undo: I tried the reverse drill bit and extract technique, but the bolts didn’t shear flat so the center punch was useless. Essentially I just made the hole in the housing a little bit bigger since I’m unable to drill in the center. None of the stuck bolts are sticking out, and they like welded into the housing. No way of getting them out. I don’t have enough thread to put a shorter bolt in either. The only option would be to carefully drill the bolts out and re-tap or helicoil. I’m definitely not confident on doing either so I’ll most likely take it to a marine service center right down the road. Without these bolts, water will just leak out the side. How screwed am I? I feel like I’m in way over my head and don’t want to make matters worse. Is my Mercury service center going to be able to fix this? Preventative maintenance my ass!!! I can’t believe the thermostat cover is bolted through the water jacket and into the cast aluminum engine block. ANY help would be appreciated. Thank you!
Cory
Wondering if anybody has any ideas or am I just screwed!?
My 20 hp Mercury outboard wasn’t spitting watter so I replaced the impeller and seals on the lower unit. Everything went smoothly. Now let’s rewind a little bit; Before my parts came for the impeller replacement, I decided to check the thermostat. Only 2 bolts on the thermostat cover, what’s the big deal. BIGGEST MISTAKE EVER!!!!! This one decision has led me to hours and hours of scratching my head, cursing, and most likely paying $$$$$$ for repairs. Both of the bolts sheared right away. The bolts sheared so far down, I had to take the water jacket cover off to see them. This is the part I wish I could undo: I tried the reverse drill bit and extract technique, but the bolts didn’t shear flat so the center punch was useless. Essentially I just made the hole in the housing a little bit bigger since I’m unable to drill in the center. None of the stuck bolts are sticking out, and they like welded into the housing. No way of getting them out. I don’t have enough thread to put a shorter bolt in either. The only option would be to carefully drill the bolts out and re-tap or helicoil. I’m definitely not confident on doing either so I’ll most likely take it to a marine service center right down the road. Without these bolts, water will just leak out the side. How screwed am I? I feel like I’m in way over my head and don’t want to make matters worse. Is my Mercury service center going to be able to fix this? Preventative maintenance my ass!!! I can’t believe the thermostat cover is bolted through the water jacket and into the cast aluminum engine block. ANY help would be appreciated. Thank you!
Cory
