I was given a 1982 Evinrude 4 HP 2 cylinder 2 stroke outboard. I endeavor to keep a positive attitude. I have spent a fair amount of time replacing worn and broken parts. Presently my effort to replace the water pump impeller has me stalled in the water, so to speak.
Two bolts hold the lower gear case to the midsection housing. On the long shaft motors, a five inch tall extension housing fits between the midsection and the gear case. On the longshaft, the two gear case mounting bolts are about 7 inches long and go from the gear case straight through the extension housing into the threaded portion of the midsection housing. The long mounting bolts go through drilled out castings inside the extention housing.
I attempted to removed the mounting bolts but I rounded off one bolt head that I eventually filed and drilled off the head. The other bolt head I snapped off after twisting it a full rotation.
I had been working on the motor upside down holding it by the extention housing plate. Hammering the headless bolts downwards with the intent of separating the midsection from the extension housing was unsuccessful. Heating the inside castings, liberally spraying Liquid Wrench and hammering on the mounting bolts, I saw no movement after several tries. There is no visible separation at the seam between the midsection and extention housing. I don't have drills long enough to drill out the bolts. I am out of ideas. Is this something a outboard motor shop could easily do? Steel bolts in aluminum housing are just the worst!
Thanks in advance for any advice.
Rob Harold
Two bolts hold the lower gear case to the midsection housing. On the long shaft motors, a five inch tall extension housing fits between the midsection and the gear case. On the longshaft, the two gear case mounting bolts are about 7 inches long and go from the gear case straight through the extension housing into the threaded portion of the midsection housing. The long mounting bolts go through drilled out castings inside the extention housing.
I attempted to removed the mounting bolts but I rounded off one bolt head that I eventually filed and drilled off the head. The other bolt head I snapped off after twisting it a full rotation.
I had been working on the motor upside down holding it by the extention housing plate. Hammering the headless bolts downwards with the intent of separating the midsection from the extension housing was unsuccessful. Heating the inside castings, liberally spraying Liquid Wrench and hammering on the mounting bolts, I saw no movement after several tries. There is no visible separation at the seam between the midsection and extention housing. I don't have drills long enough to drill out the bolts. I am out of ideas. Is this something a outboard motor shop could easily do? Steel bolts in aluminum housing are just the worst!
Thanks in advance for any advice.
Rob Harold