alpha one gen 2 bellhousing broke at exhaust bellow mount (nipple?)

brunolund

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I just took a new to me 99 searay with a 3.0 mercruiser out for a test run. all seemed well until i pulled it out and noticed that the exhaust bellows were hanging loose. the nipple(?) that it mounts to on the bellhousing broke clean off. the bellows itself is still intact. I didn’t feel the boat hit anything on the water, but it’s possible. zero marks anywhere else i can see, including the prop. I also noticed the shift cable boot is separated, and I took on a good amount of water. no problem there as it’s an older boat and to be expected. i did look at the bellows quickly when i bought the boat, and don’t notice anything wrong. I can change the bellows easy enough. But how do you break off the part that the exhaust bellows goes around? it looks like a fresh clean break to me, with no signs of previous cracking. And assuming there is nothing else broken on the bellhousing when i take it off, 1. can that piece be welded back on if i can get the gig torch in there? 2. any reason i couldn’t run it like it is, as i assume its similar to running with an exhaust boot instead of the bellows( if that makes sense?) I will be looking for a good used bellhousing, but don’t really want to dump $1000.00 for a new one if i don’t absolutely need to. thx.
 

Bondo

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as i assume its similar to running with an exhaust boot instead of the bellows( if that makes sense?)
Ayuh,...... Donno what happened nor how,.....
As for welding it back together, tig, or mig might work, with it on the bench, not on the boat,....
'n, without pictures, I Guess it could be run, as is,.....
 

brunolund

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you sure its a bellow and not a sleeve?
absolutely. the bellows was still intact, with the aluminum piece still in the end. not sure what that piece is actually called, but it’s about a 2 1/2” tube (nipple) that the bellows connects to. i’ll try to get some pics tonight. might be a couple days before i get to taking the bellhousing off though.
 

brunolund

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does anyone know if an alpha one gen 1 bellhousing will work? they’re different part numbers, so I assume not, but figured i’d ask in case.
 

Bondo

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does anyone know if an alpha one gen 1 bellhousing will work? they’re different part numbers, so I assume not, but figured i’d ask in case.
Nope, you need the Gen.II
 

brunolund

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got it off today. still don’t know how it broke. not sure welding will work, as i don’t think i can get my tig torch in there. but i’ll try. might have to try oxy/ acetylene welding!! has anybody seen one break like this while running? i still don’t think we hit anything, although that’s all i can think of.
 

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Scott06

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got it off today. still don’t know how it broke. not sure welding will work, as i don’t think i can get my tig torch in there. but i’ll try. might have to try oxy/ acetylene welding!! has anybody seen one break like this while running? i still don’t think we hit anything, although that’s all i can think of.
I can only figure you hit something never seen one break there are there is no stress on it.

I would think you can get in there enough with a TIG with a flat back cap and short tungsten. You don't have to completely weld 360 * it as it is open to the water anyways...

Alternatively you could put a exhaust tube on and not worry about it too much
 

brunolund

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I was able to get in there with the tig torch and weld it 360 degrees. man, that is a dirty casting!! i cleaned and sandblasted it as best as possible, followed by a SS wire brushing, and wiped with acetone. It still floated a ton of crap out of the weld! but it looks like it will work just fine. Thx everyone.
I must have hit something, but damn, that’s gotta be a fluke to hit there. no damage anywhere else, and definitely didn’t feel anything.
 

Scott06

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I was able to get in there with the tig torch and weld it 360 degrees. man, that is a dirty casting!! i cleaned and sandblasted it as best as possible, followed by a SS wire brushing, and wiped with acetone. It still floated a ton of crap out of the weld! but it looks like it will work just fine. Thx everyone.
I must have hit something, but damn, that’s gotta be a fluke to hit there. no damage anywhere else, and definitely didn’t feel anything.
yeah I often find on dirty castings you have to heat it with the tig torch almost forming a bead just to get the junk up on the surface and wire brush it. Saw it on a welding you tube channel where I guy was welding an old motorcycle transmission housing.

Sounds like you will be fine with the repair
 
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