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Busted Stud

P

pwskicat

Regular Contributor
1984 Evinrude E30ECRR (30 hp)
Ser: F036841
I had to remove the starter to pull/clean the carb, and when I reinstalled the starter, I over-tightened one of the nuts on the starter bracket and snapped the mounting stud. I got the OEM part from a local shop, and after doing a lousy job drilling out the old stud, chose to make the repair using original JB Weld 2-part resin epoxy, setting the stud in the resin because this mounting sits under the flywheel and is very hard to reach/drill. The repair seemed to work fine, but the last time I took the boat out, it failed; the JB Weld cracked, but the surround metal is fine. I recently watched a Project Farm YT video (link below), and noticed one major thing I did wrong, which was to not drill out the hole to a larger, consistent size to give the JB Weld more surface area. I am thinking of trying this repair again, correcting my drilling error and using the winning product from the video, JB Weld Epoxy Putty: https://www.amazon.com/gp/product/B...&linkId=78ff060242475aeb03bf1612660f08db&th=1

NOTE: The mounting is part of a plate that's on the front (boat side) of the engine that holds the carb (intake manifold?). I think it's aluminum. Any tips/products y'all might suggest to give me a better shot at success are appreciated. It's been a great little pontoon motor, and I hate to think that I kilt it.


Many thanks, PW
EvinrudeStarterMount.jpg
 
You are never going to have any chance of JBWelding a bolt in that hole, it just ain't gonna happen. You need to try and drill it out and install a helicoil so you have something for the threads to bite.
Since steel drills harder than aluminum you'll need to remove that little crescent shaped bit of bolt still lingering in the top of the hole, the try to drill it to a round size centered on the location you want the final stud to be. At this point the hole is so big you might need to use a timesert or even two nested.

Next time you break a bolt bring it to someone who has a welder since I can get broken bolt out of aluminum 99.9% of the time without damaging anything, it's a much better option.
 
Be very careful as if you drill to deep or off center you can bust thru into crankcase and put shavings inside engine.
 
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