When Simple repairs go bad....

[kevlar3000]

I just did a fuel pump rebuild on my 77 1150 Merc. Simple enough for your average monkey, but get me involved and... As I was removing one of the mounting bolts the head of the bolt snapped. No biggie I figured, just fish it out when the pump is off of the mount. Well, the bolt broke flush with the threads, So I get my screw extractor and THAT **** THING BREAKS IN THE BOLT, IT IS NOW ALSO FLUSH ON THE MOUNT!!!! I am unable to re-drill it out it seems, as my metal bit makes no progress in the broken extractor. So<br />any of you pros know any jury rigging I could do to re-mount the pump? What I have done is got some longer bolts and attached them with nuts to the bottom of the pump, I can tighten them good but I am getting just a tiny bit of leaking out of one side of the pump. In turn the boat seems to run a 2 or 3 miles per hr slower. Any thoughts would be of great help.

 

[mbb]

Re: When Simple repairs go bad....

Use a dremel tool with a cutting wheel on it to slot the extractor/bolt, use screwdriver in slot and remove the hardened extractor tip.,soak w/penetrating oil and try to extract again. If it wont extract you could have to drill out and re-tap threads, or drill oversize and put in helicoil. the round cutting wheel on dremel tool will cut into mounting flange next to hole, but those small cuts can be filled with JBweld,and sanded flush so that gasket. Good Luck.

 

[kevlar3000]

Re: When Simple repairs go bad....

Thanks a bunch, I can already feel the need to drill and re tap, it is strong like the dark side of the force...

 

[12Footer]

Re: When Simple repairs go bad....

LOL. I'm allways doing stuff like that!<br />Dangol corrosion on outboards! They ought to <br />sell the stuff under the "Locktite" brandname!<br />Jbb has the only answer too, besides replacing the case (yuk).<br />Also, think about drilling a small hole close to the broken bolt,and retap it for a new bolt. Then,jb weld the old site on the pump body, and drill the pump body for the new bolt site.

 

[kevlar3000]

Re: When Simple repairs go bad....

Hey guys, Thanks again for the advice!! Hell, it may not matter as summer in Minnesota only lasts 4 and a half days. I got this snowmobile question......