Motor Cover Repair

[KLINDWW]

I am redoing my motor cover off my 77 Johnson. It has stress cracks on the corners that I was going to repair before I repainted it. I was going to grind the cracks out and lay in some mat with epoxy resin. I was thinking about using some stuff from West Marine called G/Flex 650. It sounded like it had more flexability which I thought might be in order at these corners. I was wondering if I was on the right track and if any body might have and other ideas or pointers.

 

[jonesg]

Re: Motor Cover Repair

I would put patches on the inside, then the outside is just cosmetic repairs.

 

[5150abf]

Re: Motor Cover Repair

Concure, don't know how much body work you have done but it is very dificult to get something flat and level after you alter it, especially something with a compound curve like a motor cover.

Do all your work inside then the outside is only cosmetic and you still have the original lines to work with, in other words make the cover strong on the inside where no one will will see it, big patch well beyond cracks, then just fill the cracks on the outside and sand again using the original lines.

 

[KLINDWW]

Re: Motor Cover Repair

Thanks for the replies. I would like to build it up on the inside, but the cracks are at the bottom corners where the motor cover gasket is and where it sets on the lower motor cover and then goes around the outside of the lower motor cover. So any excess buildup on the inside would interfere with the fit.I do agree that the repair will have to be made from both sides though so some grinding on both sides will be in order. I tried grinding the outside down just a small amount and made a repair with Marine Tex, but the cracks came right thru on the first or second time out. When I was picking up the epoxy last night I saw some stuff call Crack Creap or something like that. I was even thinking about applying this prior to the repair to try and seal the cracks up. Anybody have any experience with this stuff? 5150 your comment about the compound lines is a good one, but yes I have done my share of bodywork and this shouldn?t be a problem. I have the motor cover stripped down bare and just wanted to make sure that I took my best shot a making a permanent repair. I?m sure this is a common problem and thought that maybe someone had found the perfect solution.

 

[kandil]

Re: Motor Cover Repair

I would look for a used one that is in a better shap than yours you can find it all the time on ebay.

 

[DJ]

Re: Motor Cover Repair

I would look for a used one that is in a better shap than yours you can find it aome time on ebay.

Ditto. They are a dime a dozen on ebay or at: www.tcoutboard.com

Those stress cracks are cosmetic and most hoods cracked like that.

When I "fix" a hood, I just fill the cracks, from the outside with Marine Tex, sand and paint. I never see them (cracks) again.

They crack because some Bozo, along the line, dropped/mishandled it.