Weird situation, looking for advice/how to repair

[jitterbug127]

I finally found my keeper motor on Sunday. 1980 long shaft Johnson 15 hp. Went and looked at it and it fired up on the first use of the electric starter. Pumped water beautifully, purred like a kitten, shifted smoothly, compression 105/105, clean gear lube. I’ve been looking for awhile and to say the least I was sold.

Yesterday I tried to get a piece of hose out from under one the wheels of my stand and my outboard motor stand fell over. My motor was on the stand. I had the cowling off and it landed port side down on the idle speed control. The threaded plastic piece connected to the knob also broke. I ordered new on these parts and thought not a huge deal. It got worse the farther I went.

I go to put the cowling back on and realize it won’t go back on. The left side of my lower cowling is visibly bent. I tried taking a couple pairs to pliers to see if I could straighten if back out. I had no luck. I actually broke a little bit of the aluminum off trying to move it.

I’ve found some lower cowling on eBay for around $50. I can order one and I think ultimately this will be what I do, but before I do that does anyone have suggestions how to fix this problem without replacing the lower cowling?

I’m about 4 months into my outboard motor journey. How easy/hard will it be for me to replace this part? How logical is it. I can get my cowling back on most of the way now but I can’t latch it. Also my starter will fire but not have enough power to start my engine.

 

[jitterbug127]

Pictures

 

[jimmbo]

You've already learned about the Properties of the Metal the Cowl Pan is made of. The Blow that bent/twisted it was spread over a bigger area, and all at once, than what you are doing by prying a bit here and there. You say it landed Face first, busting the carb Mixture Control, or did it land on the Port Side and bust the Idle Speed Control/Stop?

 

[jitterbug127]

You've already learned about the Properties of the Metal the Cowl Pan is made of. The Blow that bent/twisted it was spread over a bigger area, and all at once, than what you are doing by prying a bit here and there. You say it landed Face first, busting the carb Mixture Control, or did it land on the Port Side and bust the Idle Speed Control/Stop?

It landed port side. Busting the idle speed control

 

[Crosbyman]

you may be able to rebuild the missing chip by putting a back plate held by side clamps and doing some autobody filler (with glass fibers) to close it up... then sand and paint to finish the repairs and remove the back plate. nobody will know.

 

[909]

Personal keeper motors should be absolutely perfect , IMO.
Fix it as best you can, then sell it and find another keeper.
Applying heat before bending is always a good idea, the rest is autobody work.

 

[racerone]

Magnets in the starter may be broken.-----Power head needs to come off to replace cowling.------Use the recoil to start the engine for a test run.

 

[jitterbug127]

Motor runs great with the recoil starter. Ran it down at the the river yesterday. I was unsure on bend back vs replace the lower cowling. Sounds like both options would be ok. I’ll apply some heat see what happens and replace if needed. It’s already broke, so I’m not worried about making it worse

 

[tphoyt]

Agreed on the broken magnets in the starter.
If one is cracked it will try to spin but will lack any power.

 

[jitterbug127]

Agreed on the broken magnets in the starter.
If one is cracked it will try to spin but will lack any power.

That’s exactly what’s happening

 

[909]

Try adding a rare earth (neodymium) magnet on the outside of the starter. Change positions until you feel a difference. When a magnet cracks it's done.

 

[racerone]

Starter are easy to inspect , so do not hesitate.

 

[909]

 

[racerone]

We are not sure that magnets are cracked / broken.----But oh so easy for the owner to inspect / find out what is wrong.

 

[jitterbug127]

Ordered a lower cowling today. Going to try to bend the one back and Will replace if bend is unsuccessful. I’ll get to the starter tonight or tomorrow (hopefully) busy weekend with my little man.

 

[jitterbug127]

The bending seems to be unsuccessful. I tried heat and some huge channel locks and a big wrench separately without success. I’ll just put the new lower cowling on. I’m gonna have to do some work with the broken starter anyways

 

[jitterbug127]

Any suggestions for how to bend this thing back out?

 

[909]

Apply heat.
Wedge a 2X4 against the block.
Pry .
It's hard to break by hand.

If all else fails your new metal bowl is on it's way.

 

[909]

.

 

[jitterbug127]

Apply heat.
Wedge a 2X4 against the block.
Pry .
It's hard to break by hand.

If all else fails your new metal bowl is on it's way.

Will give it a shot!!