91 Alpha One Gen II Bellows

[cain]

Gentlemen, I've read post after post regarding the replacement procedures of the Alpha One Gen II bellows. I just purchased a boat with this set-up and while conducting some routine maintenance yesterday afternoon, I discovered that the bellows on my unit are in pretty bad shape. I haven't pealed it apart to see how bad the damage is just yet. Instead, I went ahead and ordered a new transom bellows kit lastnight and started thumbing through the repair manual to see how much it entailed. I'm a fairly crafty guy when it comes to skinning my knuckles on motors; however, my experiences with the marine side of things is non-existant to date. This is my first one! The level of difficulty for this project doesn't seem to frighten me at this point. I'm fairly confident that I can do the job with the right tools. That leads me to my question: What tools do I no kidding NEED in order to perform this procedure? I have a fairly decent selection of normal shade tree tools, but I have no marine specialty tools. I see that many fellas are making certain tools (i.e. bellow expanders and crimpers) in order to get through similiar projects. I really don't plan on taking things that far in order to save a buck, I'll just purchase what I need. On the flip side, I don't want to blow a bunch of money on stuff I could do without. According to the manual, it recommends about $600 worth of specialty tools for this job. This can't be accurate, can someone identify the essentials for this job? Thanks

 

[Bondo]

Re: 91 Alpha One Gen II Bellows

Ayuh,.........

How Big is your Toolbox,..??

Most of the Speciality Tools have Work Arounds for a reasonably normally equiped Mechanic kinda Guy..........

If you're 1 of Us,..........

The Gen.II is a slight Improvement over the Older models......

 

[180shabah]

Re: 91 Alpha One Gen II Bellows

Three biggies:
-Hinge pin removal tool(less than $20) It is a 12 point, so substitution is possible.
-Shift cable socket - really just a super deep 9/16 - I made mine, took a couple of cheap deepwells(a 9/16 and another spare), welded the spare to the back end of the 9/16, I now have about a 5 1/2" deep socket.
-Installation tool for the sleeve ring inside the bellows. It is just a big disk with a step down in diameter, but this one is a must have, I fought mine for two days, (on and off). finally bought the tool and ot was done in about 50 seconds.(was about $40 from merc dealer + an 8" bolt, 2 washers and 2 nuts - I built my own driver rod)

 

[cain]

Re: 91 Alpha One Gen II Bellows

Bond-o, my toolbox has enough to rip apart and reassemble a motorcycle or car engine but then again, it's never enough. I could probably drop another $5000 in it and still not be happy. I wouldn't call myself a mechanic by any stretch of the imagination; however, I'm not afraid to get in there and get dirty. What's the worse that can happen? I take it apart, can't get it back together, and take it to one of you guys. No shame in my game. Gotta learn somehow...

180shabah, I kind of figured there was no work around for the hinge pin tool and had actually planned to fabricate something for the shift cable bellow if it posed to be a huge pain. I think it was one of your previous posts that gave me that idea. I did not have a clue about the other tool. I guess I'll have to go purchase one tomorrow if its that much easier. That's a great idea for the driver rod. I probably have that stuff laying around some where. I appreciate the response.

Either of you fellas have any other pointers for the newbee?

 

[Don S]

Re: 91 Alpha One Gen II Bellows

-Hinge pin removal tool(less than $20) It is a 12 point, so substitution is possible.

IF, you heat the hinge pin to 350?F before you try to loosen it, (it has red loctite on it) and you don't have a lot of salt water corrosion, you can usually remove it with a 1/2" allan wrench with an extention. It has 100+ ft lbs of torque on it along with the locktite.

-Shift cable socket - really just a super deep 9/16 -

That is if you are using an aftermarket cable. If using a Mercruiser cable that is teflon coated and moves very easily when installed, all you have to do is remove the white plastic end by unscrewing it. It's threaded. Now if you try this with an aftermarket cable, they are crimped in and you will need a new cable.

-Installation tool for the sleeve ring inside the bellows.

Here is another one of the aftermarket problems. With an OEM bellows, you can spary the ring and the bellows with Merc Power Tuner and push it in by hand. With aftermarket bellows it's a pain, even with the power tuner. But you can get it pushed into place. Usually requires a LOT of verbal abuse.

That power tuner also works great for making the bellows slide on.

But you will need the exhaust bellows tool, unless you use the tube.
Again, the exhaust bellows from after market suppliers is a lot stiffer than OEM and may keep sliding off......... even with bellows adhesive.

 

[Bondo]

Re: 91 Alpha One Gen II Bellows

Either of you fellas have any other pointers for the newbee?
I kind of figured there was no work around for the hinge pin tool

Ayuh,.....

A 1/2" Allen Wrench works Perfectly........

Just like taking off a Square nut with a 12 point socket........

 

[rodbolt]

Re: 91 Alpha One Gen II Bellows

actualy a square nut requires an 8pt socket but they also work well for driving on studs to aide in removal after the heads fall off(yamaha thing).
the special merc shift cable tool is a craftsman9/16 with a nut welded on it, mine is anyway.
merc plated it but did not grind off the craftsman imprint.
my hingepin tool for the past 20 years has been a 3" section of a cut off 1/2 drift pin.
any good 1/2 hex stock will work just remember to heat the pin as per the manual.
yhe driver tool for the bellows retining ring can be made or purchased or subsituted .
about the only tool that is almost mandatory is the exhasut bellows expander.
while it is possible to not use it you will find its the best 26 dollar tool in the box if you ever put on an exhaust bellows without it. dont ask.
after that a tape measure and careful attention to the service manual is all it takes.
a hint: when you remove the hinge pin,reinstall the trim switch/sender with one screw to prevent it from being crushed when you turn the gimbal ring, there again dont ask.

 

[brunolund]

Re: 91 Alpha One Gen II Bellows

i did mine with one tool that i made for the shift cable. again two 9/16 deep sockets welded together. the exhaust bellows were done with no tools, but a second and smaller pair of hands.

 

[180shabah]

Re: 91 Alpha One Gen II Bellows

a hint: when you remove the hinge pin,reinstall the trim switch/sender with one screw to prevent it from being crushed when you turn the gimbal ring, there again dont ask.

Good hint

I could have used it the first time I did bellows.

 

[Bondo]

Re: 91 Alpha One Gen II Bellows

actualy a square nut requires an 8pt socket

Ayuh,......

While an 8pt. socket is designed for Square heads,.....

Believe me,..... a 12pt. Will Work........