Merc 65hp on a Jet Star? (now with pictures!)

[Gibbles]

Re: Merc 65hp on a Jet Star?

Re: Merc 65hp on a Jet Star?

Little update

I was got the little Clinton engine running, but the inline fuel pump does not seem to be working as the engine cuts out after a short time.

So I have two choices right now, find a lawn mower fuel tank and let gravity help, or replace the fuel pump.

I found that several lawn mowers have the same type of fuel pump as do some scooters and go-carts.


And on the Merc 65hp.

I got everything back together, and jumped it off of my car battery...

Fired right up and ran for a sec and then died.

After that it would not start back up, and it had a weak/intermittent spark

After some ts I found that the engine harness plug had a very bad connection, and I decided to cut it out and spliced the wires in directly.

After that the engine started right up and runs great

I let it idle for a bit in a water tank, saw a weak pee stream, held my hand on the engine and it never got very warm, so I was thinking it was related to the thermostat.

let it run for about 8-10min and the pee stream never changed, and the engine/heads never felt hot to the touch... so I decided to jam the plastic whip from a weed wacker up the tube and after that I got a good 3ft stream...

I will run some more tests on the engine before I decide to mount it, but I have to get a new bucket first as gear box put it self in gear a few times and the torque turned the engine right into the side of my garbage can, and splashed me with about 5 gal of water.

and my bimini top came last night from iboats, looking forward to some nice fishing this weekend.

 

[GA_Boater]

Re: Merc 65hp on a Jet Star?

Re: Merc 65hp on a Jet Star?

Making some good progress. I really like your windshield, nice fit. Do you know what it came from? Nice boat doggie, too.

 

[Gibbles]

Re: Merc 65hp on a Jet Star?

Re: Merc 65hp on a Jet Star?

the donor boat was a 1975, or 73 Crestliner trihull with open bow

looked like this

And thanks, I'm liking how it's turning out

 

[GA_Boater]

Re: Merc 65hp on a Jet Star?

Re: Merc 65hp on a Jet Star?

Perfect! Another glasser gives it up to keep a tinny afloat Thanks. My Nassau has the original bubble plexi w-shield and I am thinking of changing to something like you have. It just looks right.

I know what you mean about the old Merc. My harness is falling apart. Hard to even work on repairs because it is so crumbly. I haven't touched the fuel lines, but that's coming soon too.

 

[ezmobee]

Re: Merc 65hp on a Jet Star?

Re: Merc 65hp on a Jet Star?

That's cool, I think the windshield I got for my Jupiter came from the same type of glasser

 

[Gibbles]

Re: Merc 65hp on a Jet Star? (now with pictures!)



It worked out better than I would of thought

Nice part was the set screws that allow the windsheld to adjust to the shape of the boat.


and that crestliner was a heavy boat!

it took more than I thought to rip it off of the trailer at the dump
I'm sure alot of that was floation foam saturated with water, but I sure felt that thing hit the ground when I drove the trailer out from under it.

I bet I made the day of the guy driving the crusher machine when he went over the boat

R.I.P. Crestliner

 

[Gibbles]

Re: Merc 65hp on a Jet Star? (now with pictures!)

I also got my bimini top installed yesterday, perfect fit

but it was not as long as the description suggested, but its good.

best part, the mounts the prev owner had for his bimini top worked perfect with 0 adjustment.

I plan on taking the boat out early saturday morning to the lake up the road, If I remember the camera this time I will get some pictures on the water.


And I have to do a little learning about the charging system of the mercury 650, right now if I disconnect the battery while running it shuts off.

I have no clue if this is how it is supposed to work, or if I have an issue...

all of the other outboards I have worked with don't need the battery to run...

Manual does not say anything about it, so I will prob need to connect a volt meter to my battery while running and see if there is any rise...

I may not get the 65hp mounted until this winter or spring

 

[Gibbles]

Re: Merc 65hp on a Jet Star? (now with pictures!)

I found my old impact screw driver that I got from my grandpa's tools and went to town on that old clinton

It worked like a charm and I was able to get the lower off!

I don't know what the heck they used on that screw, but I had to use the impact driver until the screw was over 1/4 out...

Impeller had a little set to it, but still flexable and no cracks!

Someone had replaced the sparkplug with in the last 2 years, but it has 0 carbon buildup on it.

Replaced it anyways, and set the gap at .025 via feeler gauge.

I made a little gas tank out of a waterbottle and set it up like an iv drip, I got the engine to stay running, but the fuel pump is passing fuel through all ends flooding the engine out, its toast...

When I took it out of the setup and held my finger over the vacuum port I got the engine to idle and run pretty well.

 

[Gibbles]

Re: Merc 65hp on a Jet Star? (now with pictures!)

I ran into another tolling motor that looks much nicer.

Guy had his ad as just Mercury trolling motor and a very bad picture of an outboard

Decided to go look at it, had a nice looking engine cover like a newer model, and its a 9.8hp (I thought mid to late 80's)

Guy said it would run then shut off after a while, compression seemed to feel ok, but it was a bit hard to pull on the cord.

I asked him if it pumped water, he said yes...

I decided to go for it ($40), came with a nice little fuel tank, and fuel line.

Got it home and sprayed seafoam deepcreep in the cylinders, and crank case and worked it untill it pulled freely.

Connected the fuel, and tried to start it, nothing...
layed the engine down and put a little fuel mix right into the engine and put it back on the stand and gave it a good pull, fired right up and idled smootly and then died.

Took the carb off and disassembled it, right now I have it sitting in carb cleaner, but I broke the little plastic venturi...

Gaskets are also toast... so I decided to put an order in for a fuel pump diaphram kit/gasket kit, and decided I better check out the impeller while I'm at it...


The impeller is the worst I have ever seen

All of the blades were gone...

it was nothing more than just a sleve around the drive shaft...


Housing was melted, and even the guide tube was deformed...

So I took a compression tester (borrowed from FIL) and checked the compression.

the cheap gauge (harbor freight) first read as 110psi on #1, the second cyl showd 93psi...
So I checked #1 again, this time it showed as 94psi, second stayed at 93psi

So it should be ok, and it did sound really good when I had it running there for a sec...

So I have a carb rebuild kit, fuel pump kit, full waterpump kit with new upper and lower housings, and the waterpump tube sleeve on order.

And the little trolling motor is a Mercury 110 9.8hp and it seems to be a 1977

I also located the Mercury attachment kit for this engine, It allows me to connect the engine controls in with the controls of my 650 (My mercury manual gave me the PN and instructions on how to connect it to this engine )

It also appears to be able to accept an electric starter, and it looks like the same part as my Mercury 200 20hp.

Once I get this going, I will need to decide what trolling motor I will keep, the mercury one will be easier to sell, and I might beable to make a little $, but it idles smoother, and it will tie in with my current controls much better...

I have 5 outboard motors right now (4 running), I think I may have a problem

 

[Gibbles]

Re: Merc 65hp on a Jet Star? (now with pictures!)

I have the new trolling motor running great, and the headcover gasket was leaking like crazy so I went ahead and replaced

Took it fishing and I loved how quiet and smooth it ran, so I have a remote kit ordered for it.

And the Merc 650

I noticed that I was leaking gear oil when tilted back for a couple days straight, I have a borrowed air compressor that I used to run nail guns while replacing my shingles, so I went ahead and drained, and tested for leaks using the air compressor and a tank of water

I'm leaking big time out of the shift shaft...

I took it apart and saw that my shift shaft is pitted pretty bad on the sealing surface...

so $50 from boats.net for a stainless shaft, and $12 from ebay for the bushing kit and I should be gtg...

and since I was paying shipping from boats.net, I went ahead and ordered a gasket for the headcover (leaking around the #2 sparkplug) and a few other minor fixes that were pretty cheap...

I got the head cover off with out breaking any bolts (rusted in there pretty bad) by going very slow and used lots of penetrating oil...

now I need to replace all of the head cover bolts while I'm at it...


I'll start work on the transom as soon as fishing season is over

 

[Gibbles]

Re: Merc 65hp on a Jet Star? (now with pictures!)

I have been a bit lazy with the pictures...

I have the 650 pretty much ready to go, fixed an oil leak in the lower and replaced the shiftshaft since it was pitted at the sealing surface, gave it a pressure test via air compressor and seems to be gtg

I had a good season with that merc 20hp 200, ran great and did not have any issues.

The Merc 9.8hp 110 ran great and made a great trolling motor, easy starting and very quiet!

--------------------

Over thanksgiving weekend I tore into the transom

Bolts would not give and most snapped off
I got the nails for the cap out with a small cold chisel

The cap is damaged pretty badly and I may just make a new one using alum channel...

And right before the end of the season the water got rough on my way back to the docks, I noticed my trolling motor mount was flexing the back of the boat, may of been related to the transom but I decided to make a change in my transom design

I was planning on taking pictures, but my wife had the camera and I was on a roll...

I bought the wood from homedepot, had nice flat surfaces, and no voids.
Home depot sliced the sheet in half long ways free of charge (to fit in my suv).

I used the old transom as a template, and used a straight edge to add a few inches to the top of the transom, and to the bottom of the transom (worked likea charm)

My Jet Star has three knee braces, and they are not centered perfectly...
I managed to make small cuts in the wood and I got a pretty tight fit between them.

Fitting the transom I installed my long shaft 20hp and decided I needed to lower my transom by an inch or so...
In the end I got a very tight fitting transom because of it, and it sits much closer to the bottom of the boat than I had planned

I used my saw and set the depth about 1/8th of an inch and made cuts in what I call the Fingers to allow room for the knee braces and rivets... (I had planned to get pictures of it...)

The two ends of the transom are almost touching the sides of the boat, a perfect fit! (pictures soon)

I found that the orig holes for the transom were not straight at all, and me not wanting to make new holes I came up with the idea of drilling just slightly on both ends of the transom while mounting, removing the transom and drilling half way through using my finger on the other side as a guide, and managed to mate up the holes perfectly.

I used the west marine epoxy and a plastic squeegee that I had left over from doing drywall to spread it around.
worked great and I managed to get my whole transom done with a little epoxy left over (qt size).

between the two pieces I spread it around on both sides of the wood, gave it a little extra and put them together, standing on and moving the pieces around to smooth it out and remove any air pockets

Clamped with the three C-clams I could find... and installed 8 screws to help press it together (I used brass as I could not find any SS)

I set the transom on a sheet of foam as a backing to protect it, and put two outboard engines, and one air compressor to keep pressure on it.

Next day I found that my new transom was glued to the foam... so after some chipping and sanding it was gtg

I had some wax paper left over from painting my house, that worked like a charm from then on

I even found that leaving the wax paper on the entire surface and using the squeegee to smooth it out worked like a charm
I was able to do the entire thing at once saving my self a few days

Transom is installed, using 5200 to seal everything that looked like water could be trapped or could be an issue later...

Gooped up the bolts real good and bolted everything down, side bolts were a serious pain...

and then the big windstorm came through... I managed to clean everything up and put the boat in the yard so it was not in a path of a tree...

and that's where I am now

Sorry about the long picture free post... :redface:

 

[Gibbles]

Re: Merc 65hp on a Jet Star? (now with pictures!)

I have been looking at steering, and I'm torn between rack and rotary...

I have seen the rack installed on another jetstar but rotary sould give more space, some of the info I have seen suggest that the unit may be a little large behind the dash?

Anyone ever install a rotary steering on a jetstar?

 

[Gibbles]

Re: Merc 65hp on a Jet Star? (now with pictures!)

Also any reason to not install my kicker directly to the transom?

With the new height of the transom I have lots of flat real-estate on the back

My trolling motor mount looks like the prev owner bent it up good, and then bent it back in shape and mounted it again... looks to be mostly garbage

 

[GLG fishing]

Re: Merc 65hp on a Jet Star? (now with pictures!)

Sounds like your boat is coming along fine.
I don't know to much about steering but have some experience with kicker mounts.
If you can, mount the kicker on the transom.
If you can, mount it on the port side.
Mount the kicker 2 inches higher than the main to clear the shaft that controls steering on the main.
Mount the kicker and check all clearance for both motors.
Buy or build a stainless steel tie bar that fits the front of the motors.
The idea is to be able to lift the kicker with the tie bar attached.
GLG

 

[Gibbles]

Re: Merc 65hp on a Jet Star? (now with pictures!)

Cool, thanks

what I have done so far;

I bought the steering adapter (thank you ebay) that was old stock mercury for my kicker, then I made a tie bar out of some threaded rod and an adjustable shackle with an eyebolt using some clevis pins to hold it on and to give me a quick disconnect..

it worked mostly, main issue i had was my mount held the kicker so much higher than the main engine I had to disconnect it to raise, and I had to give the bar a healthy bend to work correctly.

The pins gave me other challenges...

hopefully having the two engines at the same level will correct some of the issues I was having.

and the steering arm seems to give me the correct distance to turn both engines at the same rate.

And I was looking at making a new steering arm using these
http://www.ebay.com/itm/130287682468?ssPageName=STRK:MEWAX:IT&_trksid=p3984.m1423.l2649

 

[lakelover]

Re: Merc 65hp on a Jet Star? (now with pictures!)

I have been looking at steering, and I'm torn between rack and rotary...

I have seen the rack installed on another jetstar but rotary sould give more space, some of the info I have seen suggest that the unit may be a little large behind the dash?

Anyone ever install a rotary steering on a jetstar?

Well....I installed a rack and it just barely fit, after I moved the original steering wheel hole over toward center an inch or so. If I were to do it again, I would definitely go with rotary.

 

[Gibbles]

Re: Merc 65hp on a Jet Star?

Re: Merc 65hp on a Jet Star?

Well....I installed a rack and it just barely fit, after I moved the original steering wheel hole over toward center an inch or so. If I were to do it again, I would definitely go with rotary.

That I did not know, thanks


I have not been able to find any real data on how big the unit will be behind the dash yet, I did see a youtube showing the difference of the teleflex and uflex rotary units, and they appear to be a little bigger than I had thought.

but with the 20 degree mount it should give me some extra space...

And for the life of me I cannot find this one restoration thread on a jet or a jetstar where he kept the dashboard tray and used the 20 degree bezel (I like the tray and want to keep it )...

And it's amazing how little information there is on the bezels, and what one works for what type of steering :facepalm:

 

[lakelover]

Re: Merc 65hp on a Jet Star?

Re: Merc 65hp on a Jet Star?

Here are a few scans from the instructions that came with mine:

------------------------------------------------------------------------------

------------------------------------------------------------------------------

------------------------------------------------------------------------------

There are two different mounting templates supplied, one to use when using the 20 degree mount and one for the 10/90 degree mount. There is slightly different placement of the mounting holes becuase of the angles involved.

I wish I could have kept my dash tray, but my issue was leg room.

Hope this helps.

BTW, if my memory serves me correctly, and it may well not ,

 

[Gibbles]

Re: Merc 65hp on a Jet Star?

Re: Merc 65hp on a Jet Star?

Thank you


Did the unit come with the wedges or do you have to buy those separately?

 

[lakelover]

Re: Merc 65hp on a Jet Star?

Re: Merc 65hp on a Jet Star?

Available separately:

http://www.iboats.com/Wedge-Kit-20-Teleflex-Marine/dm/*******.876699449--**********.816633161--view_id.169316