damaged manifold bolt hle on block 72 65hp evinrude Help!

[Mike Giglio]

I broke one bolt removing the bolts from my exhaust manifold cover on my 72 65 hp truimph evinrude. After drilling a 1/8 hole in the bolt I broke a hardened steel easy out in the hole. Trying to remove that I broke some bits and in the process of getting all the hardened steel out of the hole I toasted the threads. I brought the boat and motor to an aluminum welder and he said he couldn't see why the hole couldn't be repaired but that also it was to deep to weld. I'm on Long Island and I'm wondering if this is something I may be able to repair or find a marine machine shop on the Island to fix for me. It would be a shame to loose the motor over this. It has been suggested to me to drill the hole out wider and thread an aluminiun bolt in its place then drill out the 1/4 20 for the manifold bolt. I was also wondering if I could just drill it out and punch in an alimunum slug secured with some JB weld or something. I've done enough damage and need some advice from anyone who has done or gotten one of these damaged holes repaired. I want to try to repair the motor before scrapping it. My dilemma is that I have to purchase the exhaust manifold inner and the one under the cover from twin city outbourds and I'm reluctant to do that unless I can either fix or get the hole fixed. For anyone familiar with the 72 65 hp evinrude it isa the bolt closest to the screw that holds the fuel pump. Thanks <br />I should have just kept drilling the hole wider before trying the punch but its too late for that. Mike Giglio

 

[papasage]

Re: damaged manifold bolt hle on block 72 65hp evinrude Help!

can you e mail me a pick of the part you need . i have a few parts for a 70 hp. that fits a 1974 70 hp 3 cylinder . it might be the same

 

[rodbolt]

Re: damaged manifold bolt hle on block 72 65hp evinrude Help!

can ya post a pic? usually we just drill it out and install a heli-coil.

 

[Mike Giglio]

Re: damaged manifold bolt hle on block 72 65hp evinrude Help!

I can't figure out how to post a pic. I checked out the help option and it says for security reasons I won't be able to attach images. Anyway, if you e-mail me directly gigman8@earthlink.net, I will be able to attach a pic. I broke an easy out in the hole and in the process of drilling it out I bored the hole out wider than the tap for a 1/4 20 heli coil. The mess of a hole is about 3/16 and not centered. Not only is the hole too wide, the hard steel pushed my bit off and the bole is off center. The bottom of the hole is below where the 1/4 20 threads were and the top of the hole is close to where the threads were. I was told from a guy at west marine I could just plug the hole with this maritex and tap and drill that. I was thinking of using maritex to secure a 1/2 inch or slighly smaller aluminum rod in the whole and taping that. A friend said I may be able to use a wide aluminum bolt, and thread it in the hole, cut and sand it and drill it out 1/4 20. The straight maritex sounds the easiest but I would prefer the advice of someone who knows much more about this stuff than myself. I did enough damage with the easy out. I also drilled a little to deep into the block and have about a 1/8 hole onto the crank vent area. Thanks Mike Giglio