Just Cracked My Cylinder Case

[brettagostini]

I'm tearing down '78 Evinrude 140Hp. After removing all the crankcase cover bolts, etc., I was trying to get it off. I guess I used to much muscle, cuz I cracked the metal on the cylinder case. If you picture where the crankcase cover gasket runs along next to the bypass, there is a thin section of metal that is the front of the upper and lower bypass. A piece of that thin section about an inch long broke out.

If my explanation is clear, Here's my question... Have I destroyed my cylinder case with that one second of carelessness? Is it possible to get the cylinder case repaired/welded, or am I screwed?

If it would help, I can upload a photo.

I'm hoping that since it's only the little piece of metal at the front of the bypass that a welding repair is possible.

Any help out there?

Thanks.

 

[Joe Reeves]

Re: Just Cracked My Cylinder Case

Take the bare crankcase to a reliable machine shop that can heil arc the broken piece back in OR make a new piece for it. I'm sure that they can resurface the heli arc portion down to factory specifications.

Make sure that they understand that you DO NOT want the original surface machined/resurfaced as that is a critical match to the other portion of the crankcase.

 

[F_R]

Re: Just Cracked My Cylinder Case

As far as the material goes, it is weldable. Find somebody that is really good at it and get his opinion.

 

[brettagostini]

Re: Just Cracked My Cylinder Case

Thanks. Here's a follow up.

I still can't get the crankcase cover off. I've removed all side bolts and main bearing bolts. I've tried banging the crankshaft with a mallet to jar it loose as my service manual says. That's when I tried prying... as my service manual says NOT to do, and ended up cracking the piece out of the cylinder case. Any tips on how to get this off? Or is there a step I am missing??

One problem I'm having (its the first time I've ever done this) is working with the powerhead in place. My manual always shows pictures of the powerhead by itself laying on a table. I haven't been able to figure out how to get the powerhead disconnedted from the lower unit yet, so I can lift it out. Any help doing that would also be greatly appreciated.