exhaust cover screws beating me down

[54bobby]

guys, i have all but 4 of the exhaust cover screws out. the 2 on the bottom, 1 on the right and 1 on the left. they're not budging PB blasted them for 2 days no go, ground the bevel off of a socket for a better fit, nope, got out my brake rotor set screw slap hammer, they just laughed it off. options?? if i use heat i need to heat the cover right? not the screw itself. hard to do on those recessed heads.

 

[boobie]

Model # ????

 

[54bobby]

Model # ????

25902, 69 22cuber, sportster

 

[maxpipefill]

Drill it out, and tap new threads for new bolts. Easy out may work. Heat, cut, whatever you have to do to get them out.

 

[oldboat1]

12 or 13 of those little puppies. Too late to rethink the original reason for removing the cover?

 

[boobie]

Have you tried a hand impact driver ??

 

[merkdawg0084]

I only had six on a 9.9. 4 came out easy, heated the other two. broke head off both, welded nuts on each one of them heated some more and got one out, had to take other to machine shop and get drilled out for 25$.. I really don't think th pb blaster works that well because it can't get to the threads. good luck my friend..

 

[54bobby]

12 or 13 of those little puppies. Too late to rethink the original reason for removing the cover?

end of last season engine began to really bog down under load. when i started looking around i found water in the gear unit, and a milky oily mix in one cylinder. the engine is 49 years old and dad bought it brand new (still have the factory box). i figured the leak into the cylinder was either from the head or exhaust gaskets. replaced the head gasket now hung up on these 4 stinkin screws. 3 of which i can't get a drill on w/o pulling the power head. i do have a local shop that specializes in older omc's. i'm wondering if he would have a quick fix cause i'm sure he's run into this before.i hope
also did a complete lower unit reseal as well as a new clutch dog.

 

[54bobby]

Have you tried a hand impact driver ??

yes, but there's just enough give in the motor even with a big guy putting all his weight up against the other side that it hops off when struck.would probably work if the power head was on a work bench but i've never pulled one before and really don't want my first time to be over a couple screws.

 

[racerone]

Best pull the powerhead off.-------just a few screws , one somewhat hidden.-----Good opportunity to service the lower crank seal.

 

[Scott Danforth]

PB blaster works OK, however Kroil or a 50%/50% mixture of ATF and acetone works better.

heat is your friend

 

[Sea Rider]

If engine was used on salt water, seems bolts are already severely seized up, remove them with extra care as recommended or will end breaking heal bolts off with remaining bolt body sitting deep inside powerhead. Better remove powerhead from pan to work much better. Will need a new base gasket and exhaust cover heat gaskets as well if found shot or breaks appart during cover removal.

Happy Boating