Installing Bay Mfg extension kit, with issues...... Drilling drive shaft hole larger

[j_k_bisson]

Wondering if anyone has ever installed a Bay mfg extension kit on a 200hp Evinrude or Johnson. The instructions are very vague. They mention drilling out the drive shaft hole using a 1 1/8" hole saw mounted on a threaded rod and jam nut. The caution that to maker sure that the hole/drill does not wander while drilling. Possible that the hole might hit a parralella passage.

What passages will I possibly hit? Also Is there any way to do this other than what they suggest? Anything I need to worry about while drilling this hole?

 

[j_k_bisson]

Re: Installing Bay Mfg extension kit, with issues...... Drilling drive shaft hole lar

Seeing as I did not get a response here is how I tackled the problem. After giving it some major thought I decided to use this set up.....



What that is is a 1" hole saw turned backwards and locked into place with a 1/2" jam nut. This acts as a pilot. And the 1 1/8" hole saw turned to cut/ream the hole to the size I wanted. It is all mounted on a fine thread drill rod. Hope this helps some one here with a simular problem some day.....

 

[boobie]

Re: Installing Bay Mfg extension kit, with issues...... Drilling drive shaft hole lar

Educate me. What's a Bay mfg ext kit and where is it used ??

 

[j_k_bisson]

Re: Installing Bay Mfg extension kit, with issues...... Drilling drive shaft hole lar

The Bay Mfg extension kit is a 5" conversion kit approved by all the marine motor manufactures. It is where the kit makes a certain length outboard 5" longers. I'll post pics tomorrow. These have been available for years for smaller (10-15hp) motors. Now they are available for bigger hp motors.

 

[boobie]

Re: Installing Bay Mfg extension kit, with issues...... Drilling drive shaft hole lar

Thank you. If I remember right there was somebody building those years ago especially for Mercs. They might have had them for OMC also. These were for the bigger mtrs.

 

[j_k_bisson]

Re: Installing Bay Mfg extension kit, with issues...... Drilling drive shaft hole lar

Here is the pic of the extension kit installed. Look for the arrow.



Not a bad kit, but make sure you check all the components. I had the sift rod bushing insert not cut to the right length. Took about 2-3 tries trying to install the lower unit before I figured it out. But over all a nice unit.

 

[boobie]

Re: Installing Bay Mfg extension kit, with issues...... Drilling drive shaft hole lar

It looks real good. Nice job done. If I may ask, what did that kit cost?

 

[j_k_bisson]

Re: Installing Bay Mfg extension kit, with issues...... Drilling drive shaft hole lar

The kits run $580 plus shipping from the manufacture. Yes I could of bought a used long shaft extention but I had the full short shaft and did not want to start ripping into the lower unit to change out the drive shaft.

 

[boobie]

Re: Installing Bay Mfg extension kit, with issues...... Drilling drive shaft hole lar

Does an extension for the d/s come with the kit?

 

[j_k_bisson]

Re: Installing Bay Mfg extension kit, with issues...... Drilling drive shaft hole lar

Yep the kit includes a stud extension for drive shaft, water tube, shift rod, and the big drive housing. Also comes with the shift rod grommet extender, and the drive shaft hole extender. These are evinrude specific I think. Don't know for sure. The only thing it did not come with was the $2 gasket needed to install the shift rod extender.

 

[ThumbPkr]

Re: Installing Bay Mfg extension kit, with issues...... Drilling drive shaft hole lar

I know that this is an old post but just had to throw this in here.I have an old 650 Merc with a 15" shaft with one of these 5" extenders on it and am having major problems just trying to get my water pump impeller changed.
I will concede that it has been a long time since the lower unit has been off of the motor but the shift shaft coupler that the spline connects to is frozen on the shift shaft and the shaft pulled out of the lower unit when it came apart.
Everything was frozen,the longer bolts were rusted and corroded,it required days of soaking with Zep45 to finally get it started moving.There is really no place that you would want to use heat in the process although I did try to heat the shift shaft coupler to remove it but all I accomplished was to melt the plastic cam which engages the reverse lock which never worked anyway and now I know why,it was never connected because there is no hole in the extension to put the rod through that activates the lock.That may have been a concious ommision on the part of the installer who may have neglected to drill the hole for it.
I am laying this out here for consideration to those who may have a similar plan in mind.
I put mine back together but cannot say if it will work until I start the engine which is not yet on my boat.It is in forward gear and sliding the linkage does not find neutral as I had hoped.The shift shaft was in the proper position when I put it back together.
There is supposed to be at least one C clip on that shift shaft that is now loose in the lower unit if it was there at all.I drained the old grease and did not see it.
My plan is to put magnetic drain plugs in and try it..........I hate to pull the lower unit apart to make things right but I may wish that I had down the road.Ron G