Just inherited Merc 402, need manuals, advice on broken starter block

[garndawg]

Howdy Gents,<br /><br />I've just inherited an old Bass Tracker II boat with a Mercury 40HP 402 on it. The motor's S/N is 4042100, so I gather that's a 1974 model.<br /><br />The motor runs, but has two things wrong with it: the power cable from motor to remote unit is dry rotted completely and the starter head bracket is cracked.<br /><br />As for the power cable, the previous owner had wrapped electrical tape along almost the entire length. I've gone ahead and ordered a new power cable from Surplus Unlimited, so that should be done shortly. Doesn't look difficult, but anybody have sage advice or any gotcha's on this job?<br /><br />The second issue is the infamous cracked starter bracket that's one piece with the head. My dad had a boat with this same problem way back and the solution was to replace the head. I've read on this board that it can be welded, and I prefer that solution, as I really don't want to tear apart a running motor. So for those of you who have done this, how well does the weld hold? Any average on time between failures? Also, is this a special weld (i.e. Aluminum, TIG, etc.) or just a basic weld? I've got no experience with welding and will have someone else do the work, but it would help to let them know what kind of job to expect.<br /><br />Last topic, I'm about to order a couple of manuals and I understand the Mercury service manual is the best for detail. However, if any of you out there has either or both an Owners Manual and a Mercury Dealers Service Manual you want to sell, I'm interested. I might consider a Seloc, but I'm not convinced there's enough detail info in that one. Save me from buying brand new manuals.<br /><br />Looking forward to hearing your experiences on those blue band 402's guys.<br /><br />Garndawg

 

[OperativeK]

Re: Just inherited Merc 402, need manuals, advice on broken starter block

I don't know how yours looks but I have a 1350 and the starter bracket was broken. Tried to have it repaired and the guys said, after two hours of work, it was a no fix.<br /><br />But that didn't stop me lol. I took a small medal bar and with little enginuity : ) fabricated a better mount than that of the original engineers. Ill post a pic tonight when I get home. It only took bending the medal bar and drilling a hole.<br /><br />By the way I took it to a very reputable aluminum welder, actually one of the largest in the Lewisville, Tx area; they work on propellers and all but because of the material the block was made of and the type of aluminums used today it just wasn't going to work. Kept breaking at the weakest point. I really suggest you talk with a fabricator and if possible get it done like mine. I will post the pics tonight.

 

[Chinewalker]

Re: Just inherited Merc 402, need manuals, advice on broken starter block

A skilled aluminum welder can probably do it up for you. It can't be done with any of the low temp (propane torch) welders - It's gotta be done right. It is possible to have it beefed up a bit in the process to prevent it from happening in the future...<br /><br />- Scott

 

[Laddies]

Re: Just inherited Merc 402, need manuals, advice on broken starter block

We have had them welded by a good welder with a tig welder, also on the 402 there is a kit to help stop that from happen that attachs on the bottom end of the starter, it did come on the later 402 engines stock--Bob

 

[garndawg]

Re: Just inherited Merc 402, need manuals, advice on broken starter block

Encouraging, Scott. Thank you.<br /><br />Bob, do you have any more detail on that add-on kit? I'm assuming this is additional structure to strengthen the assembly and is NOT a repair for an already cracked block. Yes?<br /><br />If so, it'll be interesting to see Opk's pics, as I'll bet he's jury-rigged something similar.<br /><br />Thanks, guys.

 

[OperativeK]

Re: Just inherited Merc 402, need manuals, advice on broken starter block

Ok here it is. You can see some before and after of alot of painting and dash board work I have done also. I am waiting for parts this week and then I should be ready for action. I hope the pic of the starter bracket help you.<br /><br /> http://home.1asphost.com/BIW3/collections/OldMissTheBoatProject/index.html <br /><br />The medal bar is one of the bars used to lock my toolbox. lol : ) It works. Also is a close-up of the number on the block the only I can find. Wish I could locate the darn serial model number. Doesn't much matter though.<br /><br />If the first link don't work use this one. It has more pictures than the first collection. This link will be slower though. Got emule running on my network. <br /><br /> http://opk.gotdns.org/boatproject/index.html <br /><br />Also little info the piece of medal is part of the bracket that broke off the other side:<br /> http://opk.gotdns.org/boatproject/photos/photo16.jpg <br /><br />You get a pretty good view of the one bolt which I had to screw/drill one hole for to make it work here on the left side of the screen:<br /> http://opk.gotdns.org/boatproject/photos/photo7.jpg <br /><br />The trailer had lots of rust. So far lots of work and beer have gone into it along with my paycheck.

 

[garndawg]

Re: Just inherited Merc 402, need manuals, advice on broken starter block

Interesting pics, OpK. Looks like that install should hold. Unfortunately, I don't have that kind of space on the 402. I pulled the starter motor last night and it's pretty cramped in there. There's another brace bracket that bolts on right where your bar went. I'm headed to the welder on Saturday to see what can be done. I'll take some pics and post before and after images for ya'll. Hope it works.<br /><br />Incidentally, why Ole Miss? You go to school in Oxford, MS?

 

[OperativeK]

Re: Just inherited Merc 402, need manuals, advice on broken starter block

I had the other bracket too but the bar replaced it. I would be interested in seeing yours.<br /><br />The boat was given to me by my wifes father and they used to go shrimping on it in Mississippi. He had two daughters and now I have two.<br /><br /> http://home.1asphost.com/biw3/collections/mar2005/photos/photo20.jpg <br /><br />So my theory is if I keep the girls busy and on the lake(and other sports) as they grow up maybe I can keep em out of trouble when they become teens. Plus I had a chance to give my 3 yr old a ride on a jet ski last season and you wouldn't believe the smile on her face. I want this summer to be one to remember for her. They are Jamie and Katy. Katy is 1yr old and was walking two weeks before her birthday. Im sure all the Dads can relate.

 

[garndawg]

Re: Just inherited Merc 402, need manuals, advice on broken starter block

Hmm, replaced the bracket. That's an idea...<br /><br />As to Ole Miss, I understand. I went to school at MSU, in Starkville, so Ole Miss is a in-state rivalry for us.<br /><br />Nice family you got there...

 

[phatmanmike]

Re: Just inherited Merc 402, need manuals, advice on broken starter block

had same problem with my 1980 402 40hp. i found a used block on ebay for 25 dollars and replaced the crankcase half. been running fine ever since

 

[OperativeK]

Re: Just inherited Merc 402, need manuals, advice on broken starter block

In reply to myoutboards: I didn't want to spend that type of effort on it. If I had the time i might have considered it but I would just be afraid of the same thing happening again. Now it is steal. And I think that because of the way the rod is connected and the starter spin direction it really works to my advantage to keep it like this..<br /><br />In reply to nice family thanks Garndawg.