Seeing as I don't have a water pressure gauge, I would like to add a telltale like my Evinrude has. Thought that drilling and tapping into the exhaust housing cover would work.
I went to remove the plug (mine takes a blade screwdriver) and snapped off the end of a large blade driver!
The plug looks to be stainless. Going to try an impact driver next, but thought I would ask here how you folks got the plug out without breaking the plug or cracking the head!
Well, the ol' impact driver got it loose. Woo Hoo! It's a stainless slot head plug. Who knows if it was original or something a shop installed.
I found a left over hose barb from the water pressure gauge kit for the Johnson. Its 1/4 NPT, with what looks to be 3/16" barb on it. Maybe I'll pick up the same with 1/4" barb and use 1/4 fuel line.
To test the thermostat, remove it, place it in a pan of hot water with a thermometer.
Heat it on the stove and watch to see if it opens at the correct temp.
What does the tell tale do? I am guessing it shoots a stream of water when the motor is running? Wouldn't that affect the cooling or is it not enough to have any affect?
I picked up a 1/4 hose barb (1/4 npt to 1/4 id hose) at the hardware store ($1.50) and put 1/4" fuel line on it. Drilled a 1/2" hole in the lower housing starboard side and let it stick out an inch or so. Pretty much looks like Baxtr's photo except with black fuel line. Then I took 3" of 1/4" copper tube and bent an L shape and inserted it in the fuel line. That lets me adjust the direction of the telltale from down to back to up. Makes it easier to see when it shoots up and back. Kind of neat too!