Hole in Alpha 1 lower housing

[Eastboundndown]

Here’s what I do know

Hole location: Bottom rear (closest to transom) right above tiny weep hole is now a high performance super flo hole. Appears to be located in a separate cavity in casting..isolated from shaft, gears and such at least where the hole is located..

drive: I/O alpha 1 with Merc 5.7 4bbl TBIV

Heres what I don’t know: not sure if that cavity in casting is isolated all the way up? Is this repairable or start shopping?

Thx

 

[Bondo]

Hole location: Bottom rear (closest to transom) right above tiny weep hole is now a high performance super flo hole. Appears to be located in a separate cavity in casting..isolated from shaft, gears and such at least where the hole is located..

Ayuh,..... That's lower forward, the prop is mounted on the aft end,.....

My guess is,.....
The weep hole is plugged allowin' water to be trapped in the wet side of the case, it froze, 'n blew out the castin',.....

Post a picture,..... it's most likely repairable with epoxy,.....
So long as the oil side is Ok,....

Oh,..... 'n clean out the weep holes,.....

 

[Eastboundndown]

That was my sentiment as well, but wanted to be sure. No oil leaking out.. there was a beach in there. Dug heavy **** out.. gonna use some carb cleaner and air gun before repair.. Unfortunately I have no idea where the piece went so is there any links in here that might help or does anyone reading this have any input that could help. Thx for the quick response Bondo!!!

 

[Bt Doctur]

clean the broken ares , fill with JB Weld, using a LONG drill bit, drill the repair material out from inside and drill a new drain hole in the JB Weld

 

[Bt Doctur]

vert red line, long drill bit
green box, repaired area,
blue line ,drill bit for new drain hole

 

[Eastboundndown]

You guys are the Balls!
Heres pics just Incase

 

[Bt Doctur]

GEE, right about where the green box is

 

[Eastboundndown]

Now, regarding outdrive...what will I need to re-assemble and what should I replace while I’m at it.. I’m sure I’ll need a gasket kit. I haven’t looked at bellows yet but boats been sitting for five years.. impellor?.. Please let me know what you guys think

 

[Eastboundndown]

GEE, right about where the green box is

I know.. every now and then the sun shines on every dogs a$$..

 

[Eastboundndown]

Hello All.. I wimped out on the hole drilling part of the repair and I’m prepared to take some crap for it..lol anyway I wanted to share how I went about the fix without filling entire cavity with JB and drilling. I have link to photos but I basically used a piece of aluminum flashing that I had left from home repair and rolled one end around a big screwdriver until overlapped slightly and cut excess off. Then I took a good look at cavity and tried to shape the piece accordingly. Slid it down cavity from the top until it was slightly below bottom of hole and then JB’d right over it.. I was pleased with how easy it was and I sanded it smooth then applied a skim coat of the strong original JB weld overlapping the repaired area and onto the good stuff.. when that dries completely I will sand, prime and paint a repost the finished product. Happy boating and Thx again for the help guys!

 

[Eastboundndown]

Just wanted to thank you guys for dropping some knowledge my way and update with pic of results. I am very pleased with how the repair came out! Thx again

 

[achris]

Impressive....

 

[Scott06]

Looks great. Just make sure you do go back and drill the drain hole, otherwise it will be full of water and freeze again.