I have a a 1995 25hp Mariner. I went in to replace my thermostat and in the process snapped every single one of the salt corroded bolts right off. I have tried numerous things to remedy this problem and right now I have the craziest epoxy job failing to hold everything watertight. The engine is good minus this big problem. Prior to this past week, the epoxy/ JB weld has done a good job of keeping the water jacket on and keeping me fishing, but now I am leaking salt water onto my spark plugs. It is a terrible problem, and as much as I would love to buy a new engine, I am not financially capable.
I am hoping that in charlestonfishing’s infinite wisdom and experience, that someone might have an idea or know how to help me.
Here are a few of my dumb questions again… How small are the bolts? Will an easy-out work on them? Or could they be drilled out and tapped to a larger size? How about a reversible drill and a very small left hand bit (if there is such a thing)??
I tried to tap them but that didn’t work at all. Every bolt is completely corroded in there. I think they are 1/4" bolts or smaller. I’ll have to check tomorrow. I tried the left handed bits as well, no dice. I tried using PB blaster and a few different loosening agents. I tried heat but that might have made things worse.
I want to go to a shop and have them drill me new holes on top of my existing ones that have the bolts stuck, or have them weld my water jacket cover to the block. I feel as if I am running out of options, and since money is tight, I am really hoping that there is another option out there.
I noticed in a few posts earlier than this one that someone mentioned something about burr bits. I have never heard of those before, do you know anything about them?
I’ll try to take some pictures soon, but that might take some effort since I would have to chisel away all the JB Weld that is on there now.
These are what I have and frequently use them to remove bolts. They are also great for starting a perfectly centered hole to drill and tap for a heli coil. Cobalt bits are pretty much a requirement as well.
Sounds like Matt has the best solution.
Use a carbide burr in a high speed die grinder to remove the old bolt.
Even if you have to tap to the next size up you should be ok.
Have a buddy hold a shop vac nozzle next to your tool to keep as much of the debris as possible out of your water jacket.
Or better yet, go over to MattR’s house and let him help, looks like he has the tools.
Thanks Everyone,
I appreciate the help, especially since I just started posting on the forum; even though I have been following it for over a year now.
I am about to go start working on the engine. I’ll be taking pictures to help with anyone else out there with the same problem.
Ha, I appreciate you adding light to the situation. It truly is a mess, it looks real ugly now but after I clean it up, it’ll look a bit better. I’m getting tired of learning the hard way. I spent so much money trying to do it myself, I got to the point of no return.
how about finding a good condition used waterjacket
maybe duke at dukes marine, or bob hunt, or OD Driggers, or the internet
wouldn’t cost as much as all that jb weld, and work much better
a new water jacket is about $85
I wish I could. The water jacket on this make and model is part of the cylinder head. I don’t have the time or money for all of that. I already have a water jacket cover plate, but that doesn’t alleviate the broken bolts. I really think that if this engine has any affordable hope at running a watertight cooling system; it is going to be with what MattR and I are about to do with the heli coils. I do appreciate the help though.
the waterjacket cover is what I was talking about getting another one.
yes, you still have to get fix the broken bolts.
the way matt is talking about, is the way we do it here if we cant drill and ez-out
be careful cleaning the sealing surface of the block.
you don’t want to damage the sealing surface
Drill them out with a smaller bit…all the way to the bottom.
Get them hot as **** with MAP gas or you could try a propane torch…spray them with WD-40 after they are hot. The WD acts as a refrigerant and will contract the stuck bolts out of the threads.
Machine shop trick…sometimes it works sometimes it does not, but it’s worth a shot.
Roger that chrisv, Matt and I are going to try to tackle it on Saturday. I will post some pics of the progress. I would love to be fishing on Sunday, But I have to wait for a new gasket to come in the mail. I have a second water jacket cover that I plan on using. And I will also be making sure I am careful with that cleaning process. I know how bad it would be if I had uneven surfaces between that gasket seal.
And to Haulin Tail, I tried the propane months ago to get then nice and hot in an attempt to loosen that death grip, but to no prevail. I am wondering if I had used MAP gas and the WD-40, if maybe I would have had better luck. We might try it if the Heli coil route fails.
