4.3 mercruiser starter mount repair

[a8218]

Thought I would post a few pics of my most recent problem with the boat I recently purchased. The outside starter mount broke off and the previous owner just epoxied it. Not sure how long it has ran like this, but it failed on my last trip out. When it happened I found a few post of the same thing happening to other people but not much on repair.
To start I turned down a piece of aluminum to fit. A 3/8 - 16 bolt, so I could align the piece that broke off to the threads left on the block. Aluminum, to help hold the broken off piece in place and so I could leave it in and wouldn't have to worry about the aluminum bonding to the cast. I took a couple of different sized burr bits to clean everything up and try to groove it out without touching the threads. I tigged it using 309 3/32 wire running about 75 amps. Welding very little at a time, maybe 3/4" tops and letting it completely cool before resuming. Anyway here are some pics of the repair this far.I may make up a support bracket to help support the back end. Hopefully this post will help someone. I will add more photos when this is complete.

 

[Scott Danforth]

Good luck, usually the block needs to be pulled

 

[alldodge]

Prep work looks great, sure hope you can get it repaired. If so you may be able to put up a sign to repair others. It still gets me as to how many of the 4.3's have either a bot broken without having support for the starter.

 

[a8218]

No Title

I did have to pull the motor, I should have included that in my original post. I pulled it yesterday evening around 6. installed it today around 5. wasn't a bad repair at all. it welded surprisingly well to be cast. 309 is the only wire ive had success with welding cast. ive tried the specialty rods and wire and 309 is by far the better choice welding wise. just wanted to post this little project to help someone else along and to show it can be done if your confident enough in your welding skills and have a little patience because it is very slow going.

 

[eskymo]

Previous posts have asked for info about a mercruiser bracket to help steady the starter from twisting and causing the too often breaking of starter bolts
I have tracked it down through the forums and the bracket is readilyavailable and under $20.00. madIt is a made by Mercruiser - Part # 863212.
One end of the bracket connects to the solenoid but I don't know what the other connects to on the block. If you do know--let me know at dbrobitaille@live.com.
Thanks.