I spent a few hours trying to change my impeller this weekend.
The lower unit came off great. I identified the 3 screws needed to remove the housing and had at it. This is going to be a cinch, I thought.
Well, in no time flat, two screws were snapped off and te hhproject ground to a halt. So, I bought an extractor. I drilled a hole in the top of the remaining screw and began extracting. It too snapped off (albeit a little deeper than the first two).
in any event, I now have three broken stainless steel screws, and I can't seem to get any farther. The screw remnants are about 1/4 inch below the surface of the aluminum housing AND they all have tapered points, making it impossible to set a pilot hole in the center. AND I have burned out/snapped off 4 bits trying to drill through the stainless steel.
Now, I can afford a couple more bits, but I am worried that if I drill off center, that I will damage the aluminum case. I have already damaged the housing when the bits slipped a couple of times.
The SELOC manual tells me to use a chisel to break away the housing (CAREFULLY) when this happens. I have tried to do so, but at this pace I won't be done for a week.
Has anyone been through this before. Do you have any thoughts on how to remove a damaged housing with a chisel? Or on how to remove stainless steel screws from an aluminum case.