115 Johnson Rebuild

[tward]

I am working on an old (1977) Johnson and have it completely torn down. Along thhe back of the power head there are 4 bolts that hold it to the lower unit (1 in each corner and 2 in the middle). The holes for the two in the middle are a mess, there are cracks, alot of corrosion and missing metal. I can't get anyone to agree to weld it, so I bought some high temperature epoxy putty (2400 degrees).

Now to the question. Does anyone think I can get by by filling the middle bolt holes with the putty and file everything smooth and rely on the other bolts to hold the head to the lower unit? If anyone has another idea, I am all ears. Thanks.

 

[oldcatamount]

Re: 115 Johnson Rebuild

My first reaction to your question is NO, but, what have you got to lose by trying? I wonder why no one will attemp a weld job? That's a serious motor there, lots of power and torque. Those bolts have a purpose and by-passing two of them, it will shove to pressure to the others, question is, will it do damage? You will certainly lose the seal between the powerhead and the exhaust housing but, I'd bet you can get by with it like that for a long time. Don't give up on finding someone that can weld it correctly.

 

[iwombat]

Re: 115 Johnson Rebuild

My reaction is you need to find a better welder. I've had completely grenaded cases welded back into spec. A couple of chewed and cracked bolt lugs are nothing by comparison.

Keep looking.

 

[Jayrock]

Re: 115 Johnson Rebuild

if it were possible, clean the holes up a good as you can, fill with Marine-Tex gray. Then drill and tap new holes. Could work if it is your only option... worked on my Jet ski.