Mercruiser I/O Welch plug installation

[Bud420x20]

achris There would be a gap over .090 between the plug and the backing block.

 

[achris]

Ok, with the ridge in there, just push the plug up to the ridge, and give it a hit to flatten it out.

 

[Bud420x20]

achris I had to have gotten a bad part or they changed the dimensions. I squished it flat in my vise after my attempted installation failed and it just falls in and out of the hole. The old one won't go back in without force so it's definitely a few thousandths bigger. I hope the one I just ordered works.

 

[alldodge]

Just a thought if the new one is the same. Place the old plug on a 2x4 flat, the take a ball peen hammer and place the ball against plug. Take another hammer and smack the ball peen into the plug. It will cup it slightly if not hit to hard.

Place in hole if it will fit, then use something to flatten it back out
Do wear safety glasses

Sorry I got ya off of where you needed to go at first

 

[Bud420x20]

alldodge I tried to put the old one back in when I first saw it popped out and it went in crooked so I put a small hole in it to pull it out. I didn't think this was going to turn into an ordeal or I wouldn't have ruined it.