Pin Head cooling water leak in the top of the engine block

[speckcrusader]

On our 225 Evinrude, we have a very tiny, pinhead leak on the top of the head, right near the voltage regulator, between it and the flywheel. It seems as though it is in a casting seam. We have tried every type of JB weld on it, but eventually, the water finds its way out.The cooling water pressure is at 35 psi at full throttle, which at that pressure is hard to totally seal.Some suggestions have been to drill/tap the leak and put a screw in. Be we are not ready to drill as we do not know the head thickness at that point.We are now thinking about welding it. But, we are not sure what that will do to the head at that location. Has anyone welded on an engine block while everything is in place? Is that a chancey thing, based upon the thickness of the head at that point. That "point", is the section of the head above the water cavity between the cylinder banks. As I said earlier right where the Voltage reg sits.We are concerned we will make a worse situation. We are very frustated as we cannot seem to kill this tiny, tiny leak. but, as you all know, just a splash of salt water on the coils, and that cylinder drops out.Plus, the water leaks over the engine and other components that do not like the salt water.<br /><br />Any thoughts/advice would be appreciated.<br /><br />thanks..<br /><br />David k.

 

[cowboyup]

Re: Pin Head cooling water leak in the top of the engine block

I had a similar problem with my 91 150 evi earlier this summer. Only my leak was underneath the voltage regulator, on the #1 cylinder. I was told on this forum that it was a glue seam leak from the lost foam casting process. Have you noticed rust on #1 rod or wrist pin, chatter marks where the needle bearings ride and possibly fouling #1 plug yet? Hopefully not. Don't fret. I sent mine to Precision in FL. Charged $125 for the weld. Godd luck and let us know how it turns out.

 

[Dhadley]

Re: Pin Head cooling water leak in the top of the engine block

The 225 loopers do not have the problem with the glue seam leak. <br /><br />David, its perfectly OK to weld, provided its done properly. You mention the leak is on the head but describe it as being on the block. If its on one of the heads, just get another head. If it is on the block, a good machinist can weld it up. No big deal.<br /><br />Good luck!

 

[speckcrusader]

Re: Pin Head cooling water leak in the top of the engine block

Dhadley, I misspoke..the leak is in the "block", by the voltage regulator,right above that cavity that fills with cooling water as the engine fills up. the VR sits in that cavity. As I noted, we do not know the block thickness at that point. Our engine is a looper.Thanks for your comment.<br /><br />From your large bank of knowledge, do you feel that the weld will solve our problem? I would imagine it would take just a touch at the leak point. Would you suggest any special procedure or shape of the weld?<br /><br />Thanks again for your advice.<br /><br />David k.

 

[Dhadley]

Re: Pin Head cooling water leak in the top of the engine block

Its very easily fixed. Any good welding shop can do it. Preferably a machine shop that is used to doing marine work. It may even be a crack but only leaking at one point. Doesnt matter, they'll "V" it out and weld. No big deal. Youll need to have the flywheel, stator, timer base, power pack and reg/rec removed so they have easy access to the area. <br /><br />I'm not sure how far away he is from you but D&M Block Shop in Raceland can handle the job.

 

[speckcrusader]

Re: Pin Head cooling water leak in the top of the engine block

Dhadly....thanks for the advice. We will check out the local shops here in Baton rouge or in Bay Saint Louis Miss. where the boat stays most of the time. Raceland would be a long haul for us as the boat is a 26'Scarab Sport. Do you know of anyone in the Bay St. Louis area??<br /><br />Regards,<br /><br />David

 

[Jilly - 5]

Re: Pin Head cooling water leak in the top of the engine block

Before all that dismantling and welding, I would try cleaning up the metal and putting a good glob of Marine Tex on the spot. While you have 35 psi in the block, absolute pressure in such a small leak is negligible. Marine Tex should hold. And if it holds initially, it will hold forever. Worth a cheap try first. Tex is great stuff.