Rusted and rounded aft engine nuts on a johnson V4

[spybot]

You can lower it a bit by taking bolts out for the 4 mounts.-----Or cut it at the front and back so it will fall on the floor in 2 pieces.

If i had a way of putting it back together i would. I suppose i could glass it back in to one piece.
Has anyone got a good way of rejoining the two halves ??
Think the split way is the way forward the higher i can drill this bolt out the better.

 

[racerone]

I have lots of those lower cowlings here.-----May not be plentiful in your area I hear !

 

[F_R]

You wrote "I want to lower the bottom cowling so i can drill horizontally in just below where the threads enter the power head."

You also might want to consider applying that strategy to those broken head bolts. Also consider cutting away the aluminum along the length of the head bolts. Then either replace the head or have it aluminum welded and redrilled to restore what you cut away.

 

[spybot]

I have lots of those lower cowlings here.-----May not be plentiful in your area I hear !

Yeah rather like hens teeth in my part of the world.

 

[spybot]

You wrote "I want to lower the bottom cowling so i can drill horizontally in just below where the threads enter the power head."

You also might want to consider applying that strategy to those broken head bolts. Also consider cutting away the aluminum along the length of the head bolts. Then either replace the head or have it aluminum welded and redrilled to restore what you cut away.

That has crossed my mind
The amount of battering the head has been given is scrap now anyways. So cutting it up is the option but only once i get this last power head bolt out. It will be a lot easier once the power head is off. Its a catch 22 really as the head has to come off to let me get full access to bolt that holds the lower cowling on.
So plan of action
Grind head off cowling bolt
Cut lower cowl in two pieces
Drill out long bolt just below where the threads start.
Pry - Hoist - Lever what ever it takes to get this SOB power head off.

 

[spybot]

All of this just so i can replace the crank seals and square of the ports.
Thank god i will only be doing this once to this motor.
Next time i see " A bargain " I will think twice. i knew there would be some stuck bolts but not to this degree.
Heyho tomorrows another day

 

[racerone]

Crank seals ( rubber ones ) are very reliable and rarely fail on these motors.----Post close up pictures of them when you get to that stage.-----You will need a 5/16"--- 12 point socket for connecting rod bolts when you get that far.

 

[spybot]

I have the thin wall socket.
Hopefully i will be at the strip down stage tomorrow evening.
Looking at the cowl i may be able just to cut a section out and drill in from there.
But will look at it some more before i make the cut.