Alpha One Upper Gear Housing Damaged (Not Gears)

[bs4690]

Hello,

I have a 1986 sylvan with a 1986 Mercruiser 3.0L 140HP and an Alpha One (Gen 1) outdrive.

Last week when I was on the water I noticed that I was overheating a bit at idle. Whenever I increased the RPM?s the temp would shoot back down to the normal operating temp in the 120?s-130?s. I figured this was probably due to a tired impeller, especially because I know it hasn?t been replaced in at least the last 5 years. So when I trailered her home I started to yank off the lower part of the drive. This is where I caused myself even more trouble?

There?s two threaded bolts that are cast into the lower part of the outdrive that go upward into the upper housing and are held on by lock nuts. When someone was trying to break the nut loose on the port side (it may or may not have been me)?this person ended up putting the side of the wrench through the cast housing of the upper unit. I?ve added some pictures of this ridiculous mess I?ve caused?

My question now is, what?s the most cost effective way to get myself back out on the water? I originally planned to get a used upper housing, pull the old gears, reinstall them into the used housing and be done. After I did my research it looks like this is easier said than done do to special tools and pullers such that are needed. Is it possible to weld the hole on this cast aluminum housing? I think it?s either try to get her welded, or purchase the SEI upper unit replacement. Any thoughts or suggestions greatly appreciated.

http://i1270.photobucket.com/albums/jj605/rts2222/0326111604c_zpssbto63xq.jpg
http://i1270.photobucket.com/albums/jj605/rts2222/20160711_193244_zpsu4pvhnxw.jpg
http://i1270.photobucket.com/albums/jj605/rts2222/20160711_193308_zpsnd5slmzp.jpg
http://i1270.photobucket.com/albums/jj605/rts2222/Resized952016071295130555_zpsdyw3dcgj.jpg

Thanks,
Bob

 

[harleyman1975]

Yes that can be repaired by a competent aluminum welder such as the local "prop shop".

 

[Rick Stephens]

I believe that location has water on both sides. Not a big deal. It can be welded easily, or even patched with JB Weld and the old chunk or a piece made to fit. Won't hurt to run it that way as long as it doesn't crack away from the hole.

 

[fishrdan]

There's nothing in that area that's going to cause issues, raw water inside and outside. You could slap it back together and run it as-is, though I would opt to repair the punched out aluminum casting. Exhaust is in that area so a weld repair would be best, but I bet a JB Weld repair would hold sufficiently....

 

[bs4690]

That's just exhaust in there? For some reason I was assuming that there was gear lube in the cavity where I put the hole because it's between the fill screws for the gear lube. I'll have to take a closer look later today!

 

[fishrdan]

The gear lube passage is close, but on the other side of the stud hole. Water and exhaust flow through that area of the upper unit, so if you did JB weld the spot, it wouldn't get burned off by the water cooled exhaust, IE, the paint isn't burned off...

If JB welding it for a repair, but sure to sand/file/grind down to bare metal, then apply the JB weld to the bare metal.

 

[stonyloam]

Yeah, I would JB in an aluminum backing plate then epoxy the pieces back in, then coat with epoxy, sand it smooth then paint it.