Long summer months

Sorry folks for the delay but thats life for ya. As i stated ive finished the gear box. Had to fabricate the shift wire along with one of the cooling tubes.

I forgot to take pictures of the work sadly. The engine is nearly together again and almost ready for carb adjustments. Dont think shes going out this year as summer is winding down.  Hopefully this winter is nice like last year i might actually get this done.

I still need to have the canvas and seats redone. The seats were original with the lone star emblem in them and id like to keep them that way.

Long winters over time to finish up

After a longish winter. Not much snow but bitter temps to be out in barn working. Got the coil seated in place and the pinion gear slipped right in. After that had to wait for forward coil to come in. Got that in and put the cover on but once the seals come in will have to remove it again to change em.

exploded view of gear case

Roller Bearing housing

Roller Bearing

Forward coil

inserting forward gear

forward gear

Inserting prop shaft

prop shaft and reverse gear

adding reverse coil

adding snap ring and gear case cover

forward view of assembly

adding pinion gear

An exploded view of the lower gear case of an electric shift outboard motor.

Parts came in, finished pulling parts

Sorry for the delay on posting.  Gear case came in, need to clean it as there is still some of the forming sand left in it.  Gear oil plus sand equals nothing good.  So it's getting cleaned first.  Had to cut out the forward coil and bearing though.

where the complete cut through ends is where the forward coil started.  Cut both sides of the case and then pried the case up slightly so that the coil and bearing came loose.  Turns out they were corroded in place.

there's the witch of a thing (aka the forward coil) that I was trying to get out with various pullers and slide hammer.

That is the bearing that sits behind the forward coil.

Now onto a game called "What could it be?"  If you remember correctly from a previous post the gear case had damage to it which is why I am rebuilding it.  The bullet cone was broken off so I decided to see what they patched with....  Here's the first picture

What could the metal piece be?  need a hint keep reading.

here's hint two which shows a bit more of what they used to patch with. can you make it out yet?  Ok the last hint is coming your way.

At this point you should be able to see what they used as filler.  If ya need another hint I'm sure there's one either floating around in your pocket or a dish in your house somewhere.  slightly smaller than a penny but worth more.

YES folks they used a dime as filler to patch a hole.  Didn't even weld it in just set it on top and poured what looked like epoxy over top of it.  I've since decided the dime needs to stay on the boat somewhere.

Waiting for parts

So I've gotten the lower unit completely disassembled now I'm waiting for parts to come in.  I scored a bonus and ordered a used gear case from a salvage yard for 150.  They called me today to let me know that due to an error (they pulled a manual shift gear case for me which won't work) I'll be getting a brand spanking new gear case (original quote of 300) for the price of a used case.  BONUS....  also waiting on the seal kit to come in as well, than re-assembly can commence.

After I finish the lower unit overhaul, the next step will be the power head (aka the actual engine) rebuilding the carbs checking the pistons, head gasket, etc.  They really weren't kidding with the joke that BOAT stands for Bring Out Another Thousand. But I love the water and am willing to do the work myself that I'm able to do which will save a bit of money plus I'll know the engine inside and out so if anything happens while out on the water, I'll be able to fix it right then and there.

Gear Case Disassembly

Gear case cover removed

Reverse snap rings you are a devil even with snap ring pliers

reverse coil

ohh look a washer/spacer... damnit all

A look in at the gears before pulling the prop shaft

Prop shaft with reverse gear attached

pitting on prop shaft

Pinion gear with some rust

Forward gear

forward gear top view

The rusted parts on the gears are surface rust only so a scrubby and some parts cleaner should do the trick and bring em back to almost new state.  Still need to remove the forward coil and bearing which the manual states to use a "suitable puller" but doesn't state what....  sigh

Drive shaft and Thrust Bearing removed

Something seems to be missing from this bearing....

drive shaft is pitted around where the thrust bearing sits

silver gob of crap is a horrible patch job for the electric shift cable

removed the silver gob of crap to show the slice through the cable.

The upper and lower gear cases are seperate.

OOOPS guess ill have to repack that bearing.  Atleast I found all the parts.

There sits the lower gear case.  Still need to pull the gears out but ran outta time before work.

Hmmm more of the silver gob crap that they tried to use as a sealant.... what's this metal piece?

Seriously what's this metal piece? it's not listed in my parts manual or repair manual.... oh crap....