"The reason no one has answere
"The reason no one has answered is because we are all afraid to. Getting the powerhead bolts out after breaking one or more is a miserable task. I don't think anyone really has a great way of fixing this. If you have never done this before, you need to realize that the bolts go from the bottom of the exhaust housing all the way up to the bottom of the powerhead casting. The housings that they pass through typically get totally loaded with salt and corrosion. The key is to not break them in the first place. Using lots of heat on the castings that the bolts pass through prior to removal is key. A light touch on the wrench is also important. Don't take this the wrong way, sometimes it is just unavoidable no matter how careful you are. Some of the tricks include drilling a hole through the exhaust housing, at a right angle to the bolt, and drilling through most of the broken bolt, thus freeing the powerhead. Even if successful, you then must have the hole that you drilled through the exhaust housing repaired. I have heard that some have had to actually destroy the exhaust housing casting to remove the powerhead. Might not be a bad idea, if you can line up a decent used replacement midsection at a good price. The only other advice not offered is the use of a decent machine shop. They have cool, interesting, expensive tools like carbide bits that can drill stainless that the average Joe does not. Good luck with this."
