Welding Cast Iron 3.0L 2003 Mercruiser

[bajaunderground]

My buddy has a 2003 Bayliner 17' (2003) with the 3.0L 4 cylinder...for this question model number doesn't really matter.

His father left him the boat when he passed away a few years ago. At some point in time the starter went out and his dad either a) replaced it himself or b) had someone replace it? No one really knows? So last season my buddy's wife was starting it at the launch and she heard a loud 'clank' and no starting. they pulled the boat out and opened the doghouse and the starter was lying in the bilge (or close to as the wires kept it closer to the block). Upon further investigation my buddy discovered 2 broken bolts (of the 3). He and another friend were able to extract one of the broken bolts and no matter how hard we tried, we couldn't extract the underside bolt (limited space, and broken deeper in the hole...we tried every extraction trick we knew...)

He took it to a good, well reputed boat shop, they pulled the motor for better access and no luck, it was buggered up. My buddy's options are to rig it (he's not the type), have a stud pressed and welded in place or replace entire block...

Any thoughts or help before he pulls the trigger on a reman short block?

Thanks!

 

[Scott Danforth]

Is there any amount of the bolts protruding from the block? If so, simply weld a nut on the remnants, then back out the old broken bolt.

If not, with motor on stand and upside down, a mag drill with and end mill in the chuck

 

[bajaunderground]

The subject bolt is broken about 1/4" into the block and all buggered. there's nothing left to drill...I thought about an endmill....I'll try that for him.

thanks Scott Danforth

 

[Scott Danforth]

If you can use a transfer punch, you can center punch it, then drill thru the broken bolt. Start with 1/8 cobalt bit and keep increasing untill you have drilled the whole bolt out. The helicoil it back to size

 

[Bondo]

Ayuh,.... Ya gotta either get the broken bolt out, or get another block,...

The starter has to be bolt mounted, a stud won't allow it to be moved into place,...

 

[gm280]

I have never heard of welding cast iron working out very well. I have seen a few braze cast iron, but never weld it. But what do I know? :noidea:

If the engine is out, I would do the drill small and increase to get it back to something correct. But even that may end up messing the block up. Other then that, I don't know. JMHO

 

[bajaunderground]

Thanks guys...we've done all the above (which is why it's buggered). He's got two other bolts and it was used for at least 6 years that way. For the price of a new block and all the labor, I'd chance it with 2 bolts? I know starters produce a ton of torque...he never boats w/o another boat, so the risk of being stranded is limited.

 

[Bondo]

He's got two other bolts and it was used for at least 6 years that way.

Ayuh,.... What "2 Other Bolts",..??

A chevy starter is only held on with 2 bolts, unless ya count the little forward brace,....

 

[bajaunderground]

Ayuh,.... What "2 Other Bolts",..??

A chevy starter is only held on with 2 bolts, unless ya count the little forward brace,....

Maybe that's what the owner is referring to? I've never owned a 3.0L, nor have I removed my starter on my 5.7GXi

 

[camalot]

We have modified a few starter bodies for this problem, the one in the pic your see a guild sleeve has been pressed in. We then use long carbide drills to get the old broken bolt out. It's never failed yet!!!!

 

[bajaunderground]

That's an idea...now I'd have to make the modification to the starter...

 

[Bondo]

.we've done all the above (which is why it's buggered).

Ayuh,..... Desperation time,....

Take a piece of 3/8" brake line/ carb fuel line, 'bout an inch or so long,...
Put it on the end of the buggered up bolt stub,....
With a mig welder, run the wire into the tubin', weldin' it to the bolt stub,....
Quench it with cold water when done to loosen the stub,....
Try turnin' it out with vise-grips on the tubin',... or weld a nut to it,...

Is this the inner, or outer bolt,..??
Blind hole, or open,..??

 

[bajaunderground]

Ayuh,..... Desperation time,....

Take a piece of 3/8" brake line/ carb fuel line, 'bout an inch or so long,...
Put it on the end of the buggered up bolt stub,....
With a mig welder, run the wire into the tubin', weldin' it to the bolt stub,....
Quench it with cold water when done to loosen the stub,....
Try turnin' it out with vise-grips on the tubin',... or weld a nut to it,...

Is this the inner, or outer bolt,..??
Blind hole, or open,..??

Inner bolt, it's been buggered by multiple attempts at center drilling and extracting. Because it was still in the boat when we were trying,the angle was very tight...the motor was pulled by reputable boat shop, they couldn't extract the remaining fragments. I think we're going to try the "sleeved" starter trick mentioned by camalot