So...in attempting to replace the water pump, I have two issues. I'm hoping the wisdom of the forum can show me the light.

First, I have a stuck bolt...well...had a stuck bolt. After loosening the bolt a half turn or so, it began to bind. Once it bound, I couldn't turn it either direction. And yes...before you ask, I did tighten the other bolts just to make sure the lower unit wasn't binding on the bolt in question. No luck. PB Blaster. No luck. Butane torch to add a bit of heat. No luck...then a little luck...its turning a bit (yay!), then uh oh. Broken bolt. See pic below.



As you can see, I managed to get the lower unit off, even with the broken bolt...but not without collateral damage. Using a rubber mallet to tap around the lower unit flange, a portion of the flange broke off. See pic below.



So now I have two problems.

- How do I extract a VERY seized bolt?
- How do I repair the broken metal lip on the lower unit?

Any suggestions about how I can do this myself, OR where I might take this to have it done professionally are welcome. Thanks in advance.


Dave

Bell Intercoolers in Bulverde is the best!! Little bit of a drive but worth it if you have the time.

Looks like a rough day bummer.id bet a welder could fix both those for ya

Give McGill's a call & discuss. Good folks & fair prices, imo.,@ least they'll give a starting point

http://mcgillprop.com/

Wallis welding in downtown Garland will fix you up I wouldn't stress about Jimmy will fix you up

Thanks for all the help guys. Honestly, I'm more worried about the stuck bolt. I continued to maul it this morning trying to get it to budge. Heat. Hammer. Vice grips. Impact extraction kit. As you can see below, the score remains Stuck Bolt 2 - David 0.



I'm not sure if someone installed this lower unit with an impact wrench, or used JB Weld, but its not coming out no matter what. Any way to drill this bolt out while still preserving the threads on the motor?

Dang! You’re like a bull in a China closet!

I wouldn’t use the heat. I would keep soaking it in PB Blaster and keep soaking. Then soak some more. Try to use an extractor socket on it. It has inverted, counter rotating “teeth” that could grab it. It socket gets tighter as it grips the stripped up bolt. If that fails, step 2 would be to cut it flush, drill it out with a small drill bit. Try a reverse drill bit extractor. If that fails, keep moving up in drill bit size. With luck, which you been having, it will loose it’s grip on the housing and come out. Or eventually you’ll have a nice smooth hole. If this happens, you’ll need to go up one size on the bolt and tap new threads into the mid section.

As for the cavitation plate, it ain’t the end of the world. But fixing it would be a good idea.

Lick your wounds, admit defeat and take it to a professional.

Both are really easy repairs for almost any decent welder or machine shop that welds aluminum. The bolt will likely be drilled out and the hole re-tapped. Neither are a big deal it'll just cost a little.

I would weld a nut on the end, let it cool down and soak it with penetrating oil. I don’t know if that can be drilled out without damaging the aluminum around it.

Drill it on out. Re-Coil is the name of the insert you can replace it with. Piece of cake since you are drilling aluminum. These new insert work great.

There is an Aggie joke somewhere in this post

This. The only question now is, which professional? Will the same professional be able to handle both?

Take one of the good bolts to a hardware store to determine thread pitch, 3/8-16, 5/16-18, etc??? and buy a replacement bolt while you are there. Look at a tap drill chart and determine the right size drill for the thread pitch. Center punch the broken off bolt. Drill the bolt out with the appropriate size drill for the tap you will use. Chase (re-tap) the threads with the appropriate tap which will clean out the rest of the bad bolt. Take the lower unit to McGills, they can fix it. Change the impeller and L/U oil while you have it apart. Bolt it back up and go fishing. OR, take it to someone who will do all of this for you!

You should give B & B propeller in mid cities a call