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Metal chunks in cylinders

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Georgiaboy67

Advanced Contributor
I have a 1996 evinrude 115 hp that is locked up. We redid the lower unit, new water pump, two new head gaskets, rebuilt the carbs, new foot, and ran about 300 yards and locked up, made a rattling noise right before it shut off. Took out the plugs won't even attempt to turn, plus the shady mechanic put 3 different spark plugs when there's only one type to use. On top of that one of the electrodes broke off. Don't know where it is, took off the cover for cylinder heads and found a lot of metal chunks in the bottom cylinder and on the top one too.
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Any idea what could have caused all Of this?
 
Okay so it turns out the power head can't be rebuilt. The marine shop that worked on it before used a blue silicone sealant not heat resistant to seal the headgaskets and it melted instantly since the engine ran too hot, got water in the cylinders, thermostats were missing pieces, stator leaking internally, crankshaft broken, flywheel missing teeth as well. Getting a remanufactured Powerhead for $4000, BUTthis also includes rebuild of water pump, carbs, and fuel lines, and also getting a 1 year warranty. Could spend another $440 for another year. Thoughts on this?
 
4k is a lot of money to spend on a 20 year old motor is my take..i was faced with a 1995 90 evinrude with similar problems in 2010 and spent a lot on parts etc and it failed again...replaced it with a new motor and glad I did..it too was expensive but with care its good to go for another 20 years..hell its only money..
 
Okay so it turns out the power head can't be rebuilt. The marine shop that worked on it before used a blue silicone sealant not heat resistant to seal the headgaskets and it melted instantly since the engine ran too hot,
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The O-rings did not fail and the pic's of cylinders you posted do not show water intrusion, the silicon be it blue or black is only to seal head to block and has nothing to do with compression. You can get a reman cheaper than that with a years warranty and pic up a used flywheel and new stator and still be below $4k
 
the Powerhead is $2390 plus the $200 core charge, they are also charging $250 to rebuild all the carbs and fuel lines, put new spark plugs in it and the new water pump kit. They are charging $700 for labor, and then there's tax, it won't be exactly $4000, as for the flywheel i might just let it run like is for now . I know a lot to spend on old motor but there's just a lot of sentimental value with this boat and motor.
 
Would it be okay to leave the flywheel like its is? And I'm sorry for the confusion but I didn't mean water in cylinders, he said something about evertthing internally is nothing but rust, because I personally looked at them before I brought it in. The cause of the piston to start breaking was a bearing failure for the picture posted earlier. Before the bearing failure the water pump had gone bad 3 years ago and had two cracked gaskets so would explain water getting in the past.
 
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