I am very impressed! You sir are a very talented man. Are you for hire? I have a couple of projects I would pay you to do.
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I am very impressed! You sir are a very talented man. Are you for hire? I have a couple of projects I would pay you to do.
Adding a few photos of the gear housing work. Had to cut 1 3/8 inch off the drive shaft which was the length of the existing spline. So I set it up to continue the existing spline and then cut off. The shaft is 60 rockwell c on the OD. so I dressed a mounted wheel to cut through the hardened surface and then cut the bulk of the spline with a woodruff key cutter ground to match the spline profile in shape and depth but narrow at the surface. I then finished the spline with another dressed mounted wheel for the finish cut.
The rest of the photos are of the welding of the lower pivot boss and the remake of the mounting flange. The boss was a straight forward job. Filling between the stud and making the flange extension was a different issue. To keep the studs from pulling toward each other from shrinkage, I turned a plug, from 6061 aluminum, that matched the taper of the water tube and socketed into the o-ring counter bore. It was made to be a drive fit into the taper and bottoming on the o-ring surface at the same time. I made it to leave a small gap between the plug and the boss to get full penetration from both front and back. It also drove down into the water tube about 1 1/4 inches. The studs remained straight and were removed for machining.
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The only way I could machine the gear housing on my mill was to mount a plate on the table to overhang off the back and spin the mill head over the unit. Made multiple bolt patterns for mounting the gear housing in 3 different positions attached with the water pump / top bearing cap bolts, 2 for machining the gear housing and 1 for attaching the upper housing with the studs after boring bottom boss without removing gear case or making adjustments so that boring the upper housing boss aligned with the lower case.
Yes there are some gas holes in my weld however they are few. The holes on the face after machining away the vertical section aft of the lower bushing were there before welding from holes in the original casting. I had tried to weld them when I welded that area but when machined I went deeper back into the original part and cut through the weld and they were even deeper than anticipated.
I would like to say to those of you that post comments and ask questions, I am sorry for slow or no responses. I find myself struggling for time to work on this project or even add to this post. I steal my lunch break time and get in almost an hour and then after work before going home a couple of hours. The hours of work in this project have become beyond reason. I am determined to see it to the end and constantly keep wondering what can or will fail. I am getting close. Will be getting the boat down in a couple of weeks for final fit up of tilt pin position and steering bar fab.
Must press on!!!!!!!!!!!!
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Freaking incredible, curious what the price tag is if someone wanted to hire you to build this turn key motor?
Dick:
NO NEED to apologize for any tardiness in post/photos on the thread. I am sure I speak for everyone who has followed you thread in saying that we are all just amazed that someone has the talent and machinery to take on such a project, much less document it as faithfully as you have done over the length of time involved.
As I am sure all the other who have followed the thread do, you have our thanks and appreciation for starting and continuing the project, much less with all the explanations and photo's attached.
The only thing or time I would be disappointed about, is if we don't get a video, with an audio of that ungodly wail that beast is sure to make, the first time you open the throttle in anger!! REALLY LOOKING FORWARD TO THAT TIME AS I AM SURE EVERYONE ELSE IS ALSO.
Exactly what Bill said! Also looking forward to the video.
I will spare you all the details, at this time, of the completion of the lower unit. I will fast forward to pictures from Sunday and tonights work. I will let the pictures speak for themselves. Still lots of small work to complete.
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Speechless
Absolutely amazing!!!! One question...what is that thing on the back of the boat on the right side?