Popular Mechanics 1962 PM38 Build [SPLASHED 2017]

[Baylinerchuck]

Not to mention dime sized holes in pistons from being too lean.

 

[pekstrom]

Just a couple of more videos of the motor behaving pretty well.

Idling nicely in the lake water. This was when the primer bulb wasn't working right and kept collapsing:

This is after I replaced the bulb. It sounds and handles so much better:

Now I can move on to making it and the tank look better. :joyous:

 

[archbuilder]

That is what a Mercury should sound like! Sweet!

 

[pekstrom]

That is what a Mercury should sound like! Sweet!

Thanks! I'm pretty happy. Well, I was... This morning we attempted to take the boat out for some family-time. Last time it behaved really well, apart from the WOT issue. This time? Not so much. As soon as I tried to get her up on planing, the engine died. It ran ok on low speed. I did also notice the bulb wouldn't come back as quickly as it should after squeezing it. So we coasted to a spot not far from the ramps and dropped the anchor so the kids could jump in and swim for a while, and then coasted back to the ramps.

So today I learned that the fuel line has a liner that protects the rubber hose from the ethanol. And that it is common for that liner to have problems, especially if you're not careful installing things like the bulb and the tank/engine fittings. And I know I had to force it onto the fittings when I swapped things around. So now the primer bulb issue and possibly the also the WOT issue makes more sense to me. I moved the tank around while working on the floors so things have flexed a bit. I have opted to order a new line complete with the engine/tank connectors installed at the factory. I will most likely also take the old one apart and see if I can fix it. But I'm tired of messing with it at this point. :lol::facepalm:

Otherwise it seems to do so much better.

 

[archbuilder]

Seems like it was the hose assembly the entire time huh?

 

[pekstrom]

Seems like it was the hose assembly the entire time huh?

Well, yeah... I'm thinking I probably caused some issues with each end when I first installed the connectors. And I'm sure I caused more damage when I flipped the bulb around. Now knowing about the lining on the inside. There was never anything visible on the line and it seemed to work when I tested the line on its own. Of course the carb and switch box caused issues as well. I've learned a lot during this process but there's so much more to learn...

I appreciate all the advice and pointers!

 

[pekstrom]

Hi everyone, hope y'all are doing well?

Ok, so it's been about a year since I posted here last so seems like it's about time. We've been enjoying the boat and have taken advantage of the nice warm weather we've been having this year. But a little voice has kept whispering to me that I need a bigger outboard. :facepalm: So from time to time I've been perusing Craig's List to see what's out there. I recently came across a Merc350 from 1963 and thought that would look real nice on the transom! So now I am embarking on a project to try to restore it to running condition. The keyword here is "try"... Right now it is in pretty poor condition but I see the potential.

​

 

[Willyclay]

Thanks for the update. Good luck with that great boat and the classic outboard motor project!

 

[archbuilder]

very cool! bigger is always better.

 

[pekstrom]

Alright, time to continue this thread... for those who are interested.

So, this is where it started:

To recap: It is a 1963 Merc 350 with a short shaft. It has electric start and remote control. I got the control with it but like the motor, it is also in pretty bad shape but has good potential I think.

The motor doesn't run, in fact it doesn't even turn. I have been working on taking it apart and discovered the reason it wouldn't turn, the cylinders are all rusted up.
I have been able to scrounge together most of the parts I'll need, including a new engine block. The challenge has been salvaging the crank shaft. Since one piston was stuck in the TDC position, I couldn't get to the nuts on the connecting rod by the crank shaft. I have tried a number of things to try and get the piston to move, but no dice. So today I got tired of waiting:

I ended up using a hacksaw to cut a slit down one side of the engine block for the stuck cylinder. Then I hammered in two flathead screwdrivers into the slit to pry it open some more. Once I had done that, I used my small sledge hammer to tap on a rod going through the sparkplug home to the top of the piston. It moved! So now I have finally gotten it out and could remove it from the crank shaft. I did notice the lower crank shaft bearing is stuck. The upper one seems ok but I'll go ahead and replace them both just to hopefully avoid problems.

I also got the flywheel off finally, after getting the proper puller for the application. The cheap one I had gotten before just wasn't cutting it. So I also have the whole stator assembly removed. It needs some help too but the coils seem ok.

That's where I am right now. I'll post some more pictures of the process so far once I have pulled them all from my phone.

 

[GA_Boater]

That's one way to cut the mustard! LOL

Good to see you you back working on the 350. Gonna be sweet on the back and the proper vintage for the PM38.

 

[pekstrom]

Alright, time to continue this thread... for those who are interested.

So, this is where it started:

The motor doesn't run, in fact it doesn't even turn. I have been working on taking it apart and discovered the reason it wouldn't turn, the cylinders are all rusted up.
[/TD]
[TD][/TD]
[TD][/TD]
[/TR]
[/TABLE]
I ended up using a hacksaw to cut a slit down one side of the engine block for the stuck cylinder. Then I hammered in two flathead screwdrivers into the slit to pry it open some more. Once I had done that, I used my small sledge hammer to tap on a rod going through the sparkplug hole to the top of the piston. It moved! So now I have finally gotten it out and could remove it from the crank shaft. I did notice the lower crank shaft bearing is stuck. The upper one seems ok but I'll go ahead and replace them both just to hopefully avoid problems.

I also got the flywheel off finally, after getting the proper puller for the application. The cheap one I had gotten before just wasn't cutting it. So I also have the whole stator assembly removed. It needs some help too but the coils seem ok.

That's where I am right now. I'll post some more pictures of the process so far once I have pulled them all from my phone.

 

[pekstrom]

Alright, time to continue this thread... for those who are interested.

So, this is where it started:

To recap: It is a 1963 Merc 350 with a short shaft. It has electric start and remote control. I got the control with it but like the motor, it is also in pretty bad shape but has good potential I think.

The motor doesn't run, in fact it doesn't even turn. I have been working on taking it apart and discovered the reason it wouldn't turn, the cylinders are all rusted up.
This is the view of the exhaust port for one of the cylinders. Not pretty.

I have been able to scrounge together most of the parts I'll need, including a new engine block. The challenge has been salvaging the crank shaft. Since one piston was stuck in the TDC position, I couldn't get to the nuts on the connecting rod by the crank shaft. I have tried a number of things to try and get the piston to move, but no dice. So today I got tired of waiting:

I ended up using a hacksaw to cut a slit down one side of the engine block for the stuck cylinder. Then I hammered in two flathead screwdrivers into the slit to pry it open some more. Once I had done that, I used my small sledge hammer to tap on a rod going through the sparkplug hole to the top of the piston. It moved! So now I have finally gotten it out and could remove it from the crank shaft. I did notice the lower crank shaft bearing is stuck. The upper one seems ok but I'll go ahead and replace them both just to hopefully avoid problems.

I also got the flywheel off finally, after getting the proper puller for the application. The cheap one I had gotten before just wasn't cutting it. So I also have the whole stator assembly removed. It needs some help too but the coils seem ok.

That's where I am right now. I'll post some more pictures of the process so far once I have pulled them all from my phone.

 

[pekstrom]

Lol! I have been trying to post this for some time and have gotten an error each time. It never occurred to me that it may have posted it anyway. I do appoligize for all the extra posts. :facepalm:

 

[pekstrom]

That's one way to cut the mustard! LOL

Good to see you you back working on the 350. Gonna be sweet on the back and the proper vintage for the PM38.

Hey GA, thanks, it's good to be back!

Yeah I have tried Blaster PB and a few other things as well as things like Metal Rescue and the like. I've lost track of everything. And nothing seemed to affect that piston in any way. So decided heck with it. :lol:

And I just realized last night that we are probably within 50 miles of each other. I didn't know that.

 

[archbuilder]

Glad to see you are back! That looks like a project you have on your hands!

 

[GA_Boater]

Hey GA, thanks, it's good to be back!

Yeah I have tried Blaster PB and a few other things as well as things like Metal Rescue and the like. I've lost track of everything. And nothing seemed to affect that piston in any way. So decided heck with it. :lol:

And I just realized last night that we are probably within 50 miles of each other. I didn't know that.

Cross country is only about 35 miles. Long way is down to 285 and up 85 - Yuck.

 

[pekstrom]

Glad to see you are back! That looks like a project you have on your hands!

Hey Archbuilder, thank you! Yeah, it sure is a project. I don't think I fully know what I have gotten myself into.

 

[pekstrom]

Cross country is only about 35 miles. Long way is down to 285 and up 85 - Yuck.

Ok, I just guesstimated, and I do prefer the cross country route for sure. We used to live in Kennesaw a number of years back. And we've to Allatoona several times, although just to one of the beaches. We didn't have a boat back then.

 

[archbuilder]

Hopefully your engine work goes smoother than mine.....It has been a bit of a circus!