El Toro 33809
Well-Known Member
In awe and pumped that he is acquiring knowledge on the Merc's. It will be very helpful to us in the future.
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Dr Honda's Islandia Project. (Engine rebuild, and other stuff)
- Thread starter Dr Honda
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In awe and pumped that he is acquiring knowledge on the Merc's. It will be very helpful to us in the future.
Dr Honda
Well-Known Member
This project has taken longer than I wanted it to... but now I'm on a mission. I want this engine together by the weekend. And thanks on the cosmetic complements. :thumbsup:
So..... With that said.....
Today, I got a few things done. I finally uncrated the crankshaft. It was sent to "Marine Crankshaft" in SoCal... and they did an excellent job. When I sent it... the seal journals were warn, and 2 of the con-rod journals were beat. (#4 was literally beat with the rod that came though the block) When it was there... I talked with them... and they said they found one other journal that needed love. So... for $500, ($450 + shipping) they made the crank look like new. That's about half of the price of a new crank.
Anyway... I pressed on a new bearing, installed the mid bearings, sealing rings... and installed a new oil gear.
So..... With that said.....
Today, I got a few things done. I finally uncrated the crankshaft. It was sent to "Marine Crankshaft" in SoCal... and they did an excellent job. When I sent it... the seal journals were warn, and 2 of the con-rod journals were beat. (#4 was literally beat with the rod that came though the block) When it was there... I talked with them... and they said they found one other journal that needed love. So... for $500, ($450 + shipping) they made the crank look like new. That's about half of the price of a new crank.
Anyway... I pressed on a new bearing, installed the mid bearings, sealing rings... and installed a new oil gear.
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Dr Honda
Sorry to intrude but I have a quick question I have a 2005 Islandia with a 250 optimax merc and tubers complain all the time about jet spray/wash hitting them in the face. I am using a 60ft tow rope and have tried a 70ft dosent seem to make a differance. Pulls fine with no issue and get up on plane quickly. Any help would be greatly appreciated....
Sorry to intrude but I have a quick question I have a 2005 Islandia with a 250 optimax merc and tubers complain all the time about jet spray/wash hitting them in the face. I am using a 60ft tow rope and have tried a 70ft dosent seem to make a differance. Pulls fine with no issue and get up on plane quickly. Any help would be greatly appreciated....
Its probably not from the jet. Its the tow rope hitting the water. There is a tow rope called a booster ball. Get it and you won't have that problem anymore. I use one with tubes. It's a rope with a big inflatable bidder in the middle. It keeps the rope off the water. They run about $75.
http://www.amazon.com/gp/product/B001Q98TNY
Dr Honda
Well-Known Member
Got some time to work on the engine today.
At first, I tried to fit all the busted parts back together... but after a while... the only part I decided to use is the big hunk from the flange. The rest was reconstructed from 0.125" 6061 plate, and I'm welding it back together using 4043 rod.
Oh... and here's a tid bit for all of you.... the fuel pump uses 2 pulse hoses. One is the hose on the front cover... and the other is simply a hole on the back cover. That hole lines up with an opening on the mount. I discovered it today while I was looking at the busted parts, and I realized that the hole continued into the reed block. So... if anyone else has to re-create the engine block, and you need to make a new fuel pump mount... make sure that pulse line is there.
It's not done yet... but it's close. I need about 2 more hours to get the case done. (TIG welding is slow) I got a headache from welding, and it was hot in my shop... so I went home.
At first, I tried to fit all the busted parts back together... but after a while... the only part I decided to use is the big hunk from the flange. The rest was reconstructed from 0.125" 6061 plate, and I'm welding it back together using 4043 rod.
Oh... and here's a tid bit for all of you.... the fuel pump uses 2 pulse hoses. One is the hose on the front cover... and the other is simply a hole on the back cover. That hole lines up with an opening on the mount. I discovered it today while I was looking at the busted parts, and I realized that the hole continued into the reed block. So... if anyone else has to re-create the engine block, and you need to make a new fuel pump mount... make sure that pulse line is there.
It's not done yet... but it's close. I need about 2 more hours to get the case done. (TIG welding is slow) I got a headache from welding, and it was hot in my shop... so I went home.
El Toro 33809
Well-Known Member
A big job for sure. How hot is it in PA? Be sure to stay hydrated.
Dr Honda
Well-Known Member
Today wasn't too bad. It started raining, and brought the temps down... but it was still humid. Tuesday/Wed was rough. I think we got close to 100. (with high humidity)
El Toro 33809
Well-Known Member
Here in Florida when it rains, it cools things down, but afterwards the humidity really climbs.
Dr Honda
Well-Known Member
The lower case is done. It's not my prettiest work... but dealing with oil soaked aluminum isn't the best material to weld on. Also, getting the torch head into the small passages wasn't easy. The case didn't seem to warp more than a thou or so... so we are still in spec. (allowed 0.004' over the length)
The only problem I found after I was done is that the fuel pump should have been mounted at a slight angle to make room for the fuel fittings. At first... I was a little pissed... but then I realized that all I have to do is change to a 90 degree fitting, and everything should be OK.
Oh... I didn't post this before... but here's a pic of the back side of the fuel pump. The busted rod beat the crap out of it. (lol)
The only problem I found after I was done is that the fuel pump should have been mounted at a slight angle to make room for the fuel fittings. At first... I was a little pissed... but then I realized that all I have to do is change to a 90 degree fitting, and everything should be OK.
Oh... I didn't post this before... but here's a pic of the back side of the fuel pump. The busted rod beat the crap out of it. (lol)
Dr Honda
Well-Known Member
3 weeks ago. (lol)
Realistically.... if I can get the block done this week... I can do the re-assembly... and then maybe get it back in the boat this weekend.?. BUT... as always... when I want to work on my own stuff, those dang customers bother me, wanting parts or service. (lol)
I guess if I can get it all warped up by the weekend of the 4th (aug) that would be OK with me.
Dr Honda
Well-Known Member
GEEEEEEEEZZZZZZZZZZZZZZZZZZZZZZZZZZ !!!!!!!!!
I swear that this project is fighting me every step... and is taking WAY too long. The summer is almost over.
Anyway... Today I finally got the fixture made to hold the engine block, so I can cut out the sleeve. If there wasn't so much other damage... I would have just taken it to a regular engine shop to have it done. BUT... since there was... I wanted to make sure it's done right.
Here's a just a short vid of my mill running, and drilling/tapping a few holes in part of the fixture.
I swear that this project is fighting me every step... and is taking WAY too long. The summer is almost over.
Anyway... Today I finally got the fixture made to hold the engine block, so I can cut out the sleeve. If there wasn't so much other damage... I would have just taken it to a regular engine shop to have it done. BUT... since there was... I wanted to make sure it's done right.
Here's a just a short vid of my mill running, and drilling/tapping a few holes in part of the fixture.
Darn, Doc that is impressive.
Is the ETA for watertesting still next weekend?
Is the ETA for watertesting still next weekend?
Dr Honda
Well-Known Member
I spent the afternoon at my shop today. I just can't find time during the week to work on things. Also, XARiUS came in to have me check the driveshaft alignment of his 95 XP project.
Anyway... I got my engine block fixure finished (that's part of it in the vid above) And, I experimented with boring the old sleeve. I bought a new boring head so I needed to figure out what the best cutting "Speeds and feeds" were.
Well... before I left the shop... I had the old sleeve out !!!
I was going to get the new sleeve put in... but I want to do a little more clean-up work on the block. BUT... there is finally a light at the end of the tunnel.
Here's some pics. (Engine block on the fixture; Finding the center; Setting the boring head; Sleeves out !)
Anyway... I got my engine block fixure finished (that's part of it in the vid above) And, I experimented with boring the old sleeve. I bought a new boring head so I needed to figure out what the best cutting "Speeds and feeds" were.
Well... before I left the shop... I had the old sleeve out !!!
I was going to get the new sleeve put in... but I want to do a little more clean-up work on the block. BUT... there is finally a light at the end of the tunnel.
Here's some pics. (Engine block on the fixture; Finding the center; Setting the boring head; Sleeves out !)
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Dr Honda
Well-Known Member
Yep... they come in handy. But... my 2 machines cost about the same as my house.Wow Beautiful!, must be nice having those machines!
Don't know... ask me again in a couple months. :thumbsup:
But... at least I know (now) that parts are very easy... but expensive. With the Merc seadoo's... don't think of them as a "Seadoo"... think of them as a Merc outboard.
brock1
New Member
GEEEEEZZZZZZZ.Those darn custromers constantly asking you to do things for them like cleaning out their carbs because they dont know how...LOL im glad im not one of them
Dr Honda
Well-Known Member
Yep... yur' lucky.
I got one guy who wants some custom wheels on his Victory... and I just don't have time. (got to finish this engine)
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