Thermostat nightmare

[lobsterboy]

while trying to remove the thermostat cover from my 1992 evinrude 88SPL I sheared off two of the three bolts. I cannot drill these out due to interference from the lower cover. The lower cover is a single piece. Need some advice on how to gain access to these bolts.

 

[C17LoadSmasher]

Re: Thermostat nightmare

An 'Easy-Out' might work. When I was a crew chief on the C-17 (heavy cargo aircraft) here at Charleston, we used them from time to time. You will have to drill a small hole into what is left of the screw/bolt, I am guessing the shank is all that is left. You then take the easy out and tap/screw it into the hole. It is reverse threaded so that by taking out the shank of the bolt it will remain tight, provided the hole mates well with it. You unscrew the bolt with vise grips or something suitable. Hope this helps. I think they sell easy outs at Sears or ACE.

 

[lobsterboy]

Re: Thermostat nightmare

To C17,<br /> <br />Thanks for the tip. I intend to perform that operation as soon as I can over come this clearance problem. The location of the thermo housing is such that I can't physically get to the shanks with a drill and an easy out. I contemplated removing the power head so I could remove the lower cover but, I want to undo as few bolts as possible. I also contemplated creating access holes thru the lower cover and pluging them with rubber hole covers when I'm thru. I finally decided to post this problem first to check out other options.

 

[almost retired again]

Re: Thermostat nightmare

Hi Lobster Boy;<br />Boy you do have problrms, you don't have any room there unless you do remove the power head and lower moter pan. Once you get the room I have found the trick to getting broke off bolts out is to put a nut over whats left of the bolt shaft, stick a wire fed welder thru the nut and weld it to the shaft. This will give you a new bolt head to work with, and also heat the shaft to aid in breaking it loose.<br />It's not a real big job getting the powerhead and lower moter pan off, but certinaly more than what you started.<br />good luck

 

[DJ]

Re: Thermostat nightmare

lobsterboy,<br /><br />It's worth the expense and hassle of removing the powerhead to get to those nasty buggers.