Re: E60TLCCR no compression on middle cylinder
Good news, back up and running, at a cost of about $400.
Split the cases and good friend daselbee measured the cylinders after honing out the middle one. It was within spec, as were the top and bottom ones. Most of the "ugly" in the middle cylinder was aluminum from the piston. Put in a new stock piston, along with new rings in the other 2. The ring gap in the middle cylinder was within spec, a little on the high side (I know, should of bored it while apart).
I found a head in Michigan, from a fresh water motor, $100 to the door. It looked almost new, and flat as a pancake, and came with the water jacket still bolted on. Got a new thermostat, and realized the old water jacket never had a thermostat in it.
I ordered a full gasket set, and didn't know that the seals and extra stuff I ordered come in the set.
Daselbee showed me the trick about aligning the rod caps, and after 8 broken bolts on the exhaust side (that was a job getting them out! and only needed one helicoil) the build went fairly simple once everything was spotlessly cleaned.
Good ol' daselbee showed me how to adjust the linkage and idle, and after 4 hours of break-in time, it's running like a new motor.
If I really knew what I was doing, I would have ordered just the gaskets, seals and o-rings that I needed, and that would have brought the rebuild price down to around $250.
Just to pass this along, in my search for a head, I found out that americanoutboard.com has about any part that your little heart may desire. They're in Maryland, and was told that they are good people to deal with. I can't confirm this.
I still have not figured out what caused this in the first place. Maybe it was in bad shape when I bought it. The prev. owner said a new impeller was installed, and with no thermostat in it, maybe he overheated it somehow. Beats me.
Thanks for all the comments, and help from daselbee. If I have any trouble with the motor, I'll let you all know. But the way it runs now, I think it'll live for quite a while.