The 2010 FrankenMerc Project

sschefer

Rear Admiral
Joined
Nov 13, 2008
Messages
4,530
Re: The 2010 FrankenMerc Project

Battery came up quick.. Gotta love the old Interstate's.

I first made sure my spark gap tester was setup for 1/4" gap and that all the cables were tight and secure.

frank1004.jpg


I hit the remote starter and the tach said 439 RPM. That's ample to do the checks that need to be done.

First I did a compression test. All cylinders were at 115 even. With a plateau finish on the cylinders this number will likely not improve after break-in and it's fine for now. I'll decide if I want to cut the heads and bring the compression up to 125 later.

Next I opened up the gap on my gap tester to 7/16 and cranked it over. I had a nice bright blue spark on all six so I closed it back down to 1/4" for the remainder of the test. There's no sense in stressing the coils like happens at 7/16 but it is a necessary test and tells you everything you need to know about your ignition systems health. When I was cranking I was producing 13.6 volts on my timing light so the charging system is healthy. No need to break out the DVA on this engine!

The next step was to rig up a Bungee cord to hold the throttle wide open and setup max advance timing. This is where the get the term WOT Timing that you see so much. I have two cylinders (3,4) that are 1 degree advanced over the rest so my WOT Timing will be 24 BTDC (numbers on the left side of "0") degrees.

Now I take the bungee off and hold the throttle against the idle stop. The intial timing can be set anywhere between 0 and 9 ATDC (numbers on the right side of "0") degrees, I set it at 4 and then leave the nut loose. The engines idle is controlled by the intial timing setting and not by anything in the fuel system. This might be hard to understand if you're use to working on your car but this is the way these motors work.

4 degrees might be a little too much and the idle will probably be around 1000 RPM but it will probably need that to get running and burn all the excess oil out. After the first 1/2 hour I'll adjust it down to 800.
 

sschefer

Rear Admiral
Joined
Nov 13, 2008
Messages
4,530
Re: The 2010 FrankenMerc Project

Whew, 7 months is how long this build took... Aint gonna make no money that way...LOL....

This does prove that it can be done but it takes a lot of scrounging for parts and a whole lot of patience waiting on things that you can't control.

There were many frustrating moments along the way but along with the frustrations came the reward of working through the difficulties and overcomming them.

I'm not grinning from ear to ear because I'm glad it's done and I know that I wll never do it again.

So what is my advice on this to you? DON'T DO IT... Buy yourself a running used motor and overhaul it when the time comes. The results can be the same and it will cost you a lot less money.

I'll stop short of ending this thread now. It wouldn't be fair to leave you hanging wondering if it ever started. I know it will but you deserve to see that too. I will have a video.

For those interested, heres a link to all the pictures I took of the project.
I hope it works, if not let me know. Sometime later, I'll organize and label them.

http://s476.photobucket.com/albums/rr121/sschefer/The 2010 FrankenMerc Project/
 

madgadget

Petty Officer 1st Class
Joined
Sep 28, 2009
Messages
281
Re: The 2010 FrankenMerc Project

Damn right I want to see this running, fitted and all sorts haha. Cant leave it as it is now :)
 

jmj120

Petty Officer 3rd Class
Joined
Jun 20, 2010
Messages
80
Re: The 2010 FrankenMerc Project

Great job. Ton of info. Thanks for taking the time to photograph and explain things.
 

luvtoboat1

Recruit
Joined
May 23, 2010
Messages
3
Re: The 2010 FrankenMerc Project

Excellent job LOTS of great info!!!!! Mines on the the stand and going to do some mild exhaust clean up thanks for all the great pic's:D And for taking the time!!!
 

sschefer

Rear Admiral
Joined
Nov 13, 2008
Messages
4,530
Re: The 2010 FrankenMerc Project

Excellent job LOTS of great info!!!!! Mines on the the stand and going to do some mild exhaust clean up thanks for all the great pic's:D And for taking the time!!!

You're welcome.

Just for info, I was going to do a 2.5 Litre next but I've changed my mind. I'm now seriously considering building an Aluminum boat from plans. My North River is a really nice boat and so is my 18' MonArk F/S but I actually like the MonArk better and I finally figured out why.. I built it the way I wanted it. I never get in that boat and say "I wish it had this or I wish that wasn't there". The NR is underpowered with it's 5.7L motor and really needs a big block. Face it, running down the lake in a fancy 40,000.00 boat and getting passed by a 2500.00 14' aluminum with a 25hp motor on it is pretty sad.

Re-Powering the NR can't be done without some major work and alteration so rather than mess up a good boat and possibly devalue it, I'll just build my own.:D I'm already dreaming about stabbing the throttle on a big ole 515 Ford.:eek:

I've already started the thread over in building and restoration.. Look for the thread Glen-L 21' Canyon.
 

luvtoboat1

Recruit
Joined
May 23, 2010
Messages
3
Re: The 2010 FrankenMerc Project

Sorry to hear you shelved the 2.5 project was looking forward to that.!! But im sure the boat project will be challenging??? And it has a ford so it will be worth following :D And good luck!!!
 

dunc333

Seaman
Joined
Dec 27, 2009
Messages
54
Re: The 2010 FrankenMerc Project

thanks mate ive been following your progress the whole way and must say it has been the best thread in any forum i can remember ,best explained engine rebuild with pics i have seen,so cant wait to see it start cheers dunc333 in aus.
 

sschefer

Rear Admiral
Joined
Nov 13, 2008
Messages
4,530
Re: The 2010 FrankenMerc Project

First - Thanks dunc333..

Frank Update - Last night I pulled old faithfull off my 18' tinny. I'm running out of shop space so rather than build yet another engine stand, I pulled the power head off, put it on the engine stand then pulled the lower and stuck it in a stand leaving me with just the mid and transom bracket. I unbolted it and leaned it up against the wall. It took about an hour.

Next I grabbed Frank with the hoist hook and rolled him, stand and all, over to the jack plate. I took the two bolts off the stand and let it drop then pushed Frank up and bolted him on.

I know not all of you have the option for a Jack or Offset Plate but if you do, I highly recommend it. If for no other reason than it being a one man job to change a motor. You'll never have to crawl the bilge again!!!!. ;)

I then rigged Frank. Connected the steering (hydraulic), and wired him up. Fuel won't be comming from my main tank. I always put fresh fuel at 35:1 mix in a two gal can on a fresh motor. That's more than enough for a 1/2 hour initial breakin run. I'll get into that more on startup day, (maybe Saturday).

When I was checking the throttle and shift I noticed that the linkage that I used was causing #1 to not close fully and when opening it was acting progressive. #1 carb was wide open but 2 and 3 were progressively less open. I didn't have enough adjustment to correct it so tonight I'll try changing it out with a linkage setup from a set of WMV's. If that doesn't work I'll mill something out of some bar stock I have.

As a side note. The WMH linkage wont work but WMV linkage and WH linkage is identical except the WMV link arms have more adjustment and the link bar is adjustable. The easy fix would be just to swap out the link bar but the bar on the WH is pinned on while the WMV's are ball/socket. Won't take more than 15 minutes to know if it's going to work. If not it's still no big deal to just fabricate something.

If everything goes according to plan and I get the apples picked and the lawns mowed I should put the juice to Frank Saturday afternoon. That could mean a break in day at Lake Sonoma on Sunday.
 

sschefer

Rear Admiral
Joined
Nov 13, 2008
Messages
4,530
Re: The 2010 FrankenMerc Project

Pics of Frank on the boat...

frank002-7.jpg


frank004-4.jpg


frank005-4.jpg


frank006-4.jpg


frank008-4.jpg


This is a video link test just wanted to be sure I could setup the video link from here rather than using YouTubereculosis. The pic is a link and will take you to my photobucket site where the video will launch. If anybody has trouble with the link please let me know and I'll fix it.

 

75TowerOfPower

Petty Officer 1st Class
Joined
Apr 17, 2009
Messages
331
Re: The 2010 FrankenMerc Project

Works great and looks great. I am very jealous, I can't imagine my boat with that beast on it.
 

sschefer

Rear Admiral
Joined
Nov 13, 2008
Messages
4,530
It's alive !!!!!

It's alive !!!!!

Here ya go --- The first thing I did before starting was to re-check everything one last time. Then I rigged up my 2 gal gas can with 7.2 ounces of QuickSilver Premium Plus blended non-synthetic oil in exactly 2 gals of Chevron 91 octane mtbe gas.

Here's the way I figure out what I need for oil... Merc say's to break a motor in you run 100:1 in the tank.. Since the ration is per gallon and oil is measured in ounces, the common denomonator is 128 so 128/100 = 1.28 ounces per gal.. Thats all good so now what is that oil pump putting into the gas since Merc is assuming we're running one. Well if we measured the output at idle we'd find that its right at 55:1 so 128/55 = 2.33. If we add the two together we get 3.61 now if we divide 128/3.61 we get 35:1 and that's what'll be in my 2 gal 30 minute break in tank. By the way, the gas can was clean but I'm still running it through my old Racor 10micron filter.

I have to warn you, this video is a little long and I had the camera taped to my hat so you would see what I was looking at. Some of the shots are a little boring.

On startup, you'll see me hit the remote starter then walk around. I was hitting the manual choke button on the enrichner. I gave it a 5 second blast with the motor trimmed all the way under. Let it sit for a few minutes then raised it up level... I guess cross drilling those carbs for the choke worked o.k. I only had to hit it for another 2 seconds and this engine was completely dry of fuel.

One last thing before the movie... The engine is running as vibration free as it looks and is the smoothest engine I've built yet... Who say's balancing is waste of time...:D I should have put a glass of wine on the timing cover;)

Now sit back and enjoy the movie --

 

sschefer

Rear Admiral
Joined
Nov 13, 2008
Messages
4,530
Re: The 2010 FrankenMerc Project

Finishing up now, I cut the attenuator box down a little because of the 1" spacer and I had to take the front cowling pin/lock off and cut the bolts off the inside of the cowling. I already had the strap down cover and cowlings from another motor so it was a perfect match..

So here's the final shots of a 150+ hp Mercury V-6 built entirely from scratch parts. The serial number on this motor is 1. It's gonna be a runner for sure... I can tell by the way it responded to throttle..

frankfinal014.jpg


frankfinal017.jpg


The END ---

frankfinal018.jpg


Thank you all for supporting me in this project... IT WAS A BLAST !!!!
 

jmj120

Petty Officer 3rd Class
Joined
Jun 20, 2010
Messages
80
Re: The 2010 FrankenMerc Project

Great job. I've got a xr6 150 I had a little trouble with and I found myself consulting your thread about as much as the service manual. Thanks for taking the time to post. I'd love to tackle something like this one day (I think). Thanks again and you've got an engine to be proud of.
 

mxzeatr

Petty Officer 2nd Class
Joined
Jun 2, 2010
Messages
188
Re: The 2010 FrankenMerc Project

Sweet build. I'd love to have that mota on the back of my boat!!!!
 

sschefer

Rear Admiral
Joined
Nov 13, 2008
Messages
4,530
Re: The 2010 FrankenMerc Project

Caught on video --- LOL in the last minute of the video, I threw it into gear. I didn't realize until now that the focus was on the seat and it was acting as a tell tale. When I put it into gear the boat/trailer moved forward into the fence and it drug the tub about a foot. Thats why I ran back there to look...

Yeahhh... now that's some power....
 
Top