Welding/repairing motor

Todd 1669 · Feb 26, 2009

I just got a 1978 Evinrude 55hp. Seems that one of the studs that the starter bolt thread into has been snapped off. By stud I mean the cast part of the crankcase that the starter bolts would thread into. Can this metal be welded and if so what kind of welding shop should I look for? I dont know what kind of metal it is but its cast. If it cant be welded are there any ideas on a fix? This is the top bolt for the starter and without *** being fixed the starter wont engage the flywheel correctly. Can this be pull started somehow?
I just bought the motor and the seller had it jury rigged to last long enough to make the sale. Starter started grinding on the flywheel 2 days after I got it home. I should have taken a better look.

splitshot · Feb 26, 2009

Re: Welding/repairing motor

there is only two ways to know for sure...post a pic on here, or take it to a welding shop they dont charge you to look at it (or they dont down here)..the block is Aluminum..do you have the piece that broke off ??

Todd 1669 · Feb 26, 2009

Re: Welding/repairing motor

I have the piece and will try and post a pic soon. I was wondering if I should look for a paticular kind of welding shop.

tashasdaddy · Feb 27, 2009

Re: Welding/repairing motor

experienced in welding alumimun. pictures: http://forums.iboats.com/showthread.php?t=285637

fixmyevinrude · Feb 27, 2009

Re: Welding/repairing motor

The welding process used to weld aluminum in known as TIG (tongston inert gas) welding. Any general weld shop should have the equipment to do this. It takes a fairly highly skilled welder to master this process, but with practice most welders can become profecient at it. If you have the broken piece there may be a good chance of welding it back on. TIG welding produces a tremendous amount of heat and I am wondering how much of your motor would have to be dsiassembled to complete the repair. Post a pic and someone may have a simpler idea that will work for you. Best of luck.

ezeke · Feb 27, 2009

Re: Welding/repairing motor

Many propeller shops are set up to do this kind of repair.

Silvertip · Feb 27, 2009

Re: Welding/repairing motor

I have seen blocks like yours (including one of mine) with a flap of the block sticking out due to a rod letting go. The flap was pushed gently back in hole and welded by an experienced welder and the engine lived on. Those engines were totally disassembled since new internals were needed however.

Todd 1669 · Feb 27, 2009

Re: Welding/repairing motor

Sorry for the bad manners and not introducing myself on the virgin post. My name is Todd, I'm 38 years old and I hail from the shores of Lake Erie at the port of Cleveland Ohio. I recently aquired a 17 Foot Mirrocraft w/said 55 hp Evinrude and a 5.5 Evinrude fisherman kicker (1960). Neither seem to be as great as advertised. THe 5.5 is at 60psi in both cylinders. Another issue for a later time. This site is a HUGE help for new boat owners and I'm learning much.
I havent had a chance to take pics yet but I will. As far as tha motor being disassembled -this stud is on the crankcase cover. How much work might be involved getting this removed and than shopped around welding shops? It looks like tha carbs/intake manifold have to be removed and then the crankcase cover. I have a little motor knowledge from tinkering around on motorcycles but no outboard experience. I already have a shop manual for it. Again, thanks for the help

splitshot · Feb 27, 2009

Re: Welding/repairing motor

to get the crank case cover off the powerhead has to come off and then apart....there is a lower bearing retainer that holds the 2 halves together

5150abf · Feb 28, 2009

Re: Welding/repairing motor

Welded aluminum for 22 years, no need to dissasemble the engine, no bigger than that peice is it won't get nearly hot enough to hurt anything.

Just tell the guy to have an air hose handy and cool it off with some air or a wet rag works well too.

Just make sure the welder you chose can actually weld aluminum, I give all the weld tests at work and EVERYONE can weld until they actually have to, don't be afraid to ask to see something aluminum he has welded.

Shouldn't be a problem in an established shop and MIG would be fine too if the part if camfered and just to be safe disconnect the battery before it is welded.

Todd 1669 · Feb 28, 2009

Re: Welding/repairing motor

Heres a photo of the broken boss with a bolt holding the snapped off piece on.

Heres a farther view

Heres a pic of it removed.
Hope these turned out. Great instructions on the link posted.

Todd 1669 · Feb 28, 2009

Re: Welding/repairing motor

A related question on this repair. I talked to a welder that claims towell versed in aluminum welding. He told me that I have to remove "both covers"before he will attempt to do the repair. I think he means the crankcase cove itself. Do I have to remove the powerhead to get this off. How much of a job is getting this crankcase cover off?
Thanks again for all that apply

5150abf · Mar 1, 2009

Re: Welding/repairing motor

No you don't need to take the motor apart, I could have that done in about 10-15 minutes, it simply isn't going to make enough heat to hurt anything.

He should be able to weld 3/4 of it which should hold that forever without problem if done right, pull the broken part off and get a decent camfer on it and do the same to the part on the motor and weld as much as he can reach.

When he is done have him hit it with an airhose, wet rag or a spray bottle with water in it, you want to cool it but not all at once.

If you wanted to weld it all the way around I think you would have to take it apart, but if it were my motor and I was welding it myself I would do it like I said and just weld what I could reach, oh, and leave the bolt in when it is welded to make sure you have the right alignment.

Probably use some Loc-Tite and don't super torque the bolt.

I have never done that particular part but I have welded a similar part on a motorcycle case.

Frankly if this guy won't do it without taking the entire engine apart find someone else to do and yes you would have to dissasmeble the entire engine.

fixmyevinrude · Mar 1, 2009

Re: Welding/repairing motor

Since you posted your pics I have a possible fix that would not involve welding. Is it possible to tap the existing boss a little deeper with a bottoming tap. Just grind the lead of a standard tap and carfully tap all the way to the bottom of the boss. You will have to still use the broken part of the boss to keep your spacing correct when you put your starter back on. You can then get a longer screw if needed and through trial and error cut it off to just the right length to get as much of the screw in the boss as possible. Don't over torque it when you reassemble it. You may want to use a little loctite to keep it from backing out. If you use loctite use the blue loctite. It is removable but will do just as good of a job for your application. Best of luck.

ezeke · Mar 1, 2009

Re: Welding/repairing motor

You might also consider tapping it for a long stud.

hammerhandle · Mar 1, 2009

Re: Welding/repairing motor

In my opinion , i dont think you will need to disassemble the crankcase halves, a competent welder should be able to weld this with out much problem.lots of good advice your getting with previous post(s). welding and also tapping slightly deeper sounds like the best way to go.aluminum should be cleaned and have a slight pre-heat before welding , i would prefer tig , but other methods will work also. It looks like there would be a possibility of a bridge to help strengthen the clamping area. did you find out what caused this to break in the first place ???? cheers !

Todd 1669 · Mar 1, 2009

Re: Welding/repairing motor

It seems that the boss is already threaded all the way to the bottom. Original bolt was a 1". Going to a 1 1/2" bolt it threads into the remaining boss around 4 1/2 turns untill bottoming out. Putting the starter with the broken piece and a lock washer it seems to hold pretty well. Frankly I think this might be the trick but I would feel alot better if it was welded. Having my 2 kids out on Lake Erie with a broken starter doesnt sound like fun.
Only thing I can think of that broke it originaly is overtorque.
Again thanks

samo_ott · Mar 1, 2009

Re: Welding/repairing motor

Another option might be to drill and tap the hole one size larger as it will have a better grip.

Also if you go the welding route I sure hope you will remove that fuel pump and all the lines around it!

Benny1963 · Mar 1, 2009

Re: Welding/repairing motor

had the exact same prob on 50 evin
boat guy by my house welded it with the bolt holding it in place .let cool removed bolt and finished welding what he could get
never had another prob with it.

Welding/repairing motor

Seaman Apprentice

Petty Officer 1st Class

Seaman Apprentice

Honorary Moderator Emeritus

Petty Officer 1st Class

Supreme Mariner

Supreme Mariner

Seaman Apprentice

Petty Officer 1st Class

Vice Admiral

Seaman Apprentice

Seaman Apprentice

Vice Admiral

Petty Officer 1st Class

Supreme Mariner

Petty Officer 3rd Class

Seaman Apprentice

Vice Admiral

Lieutenant