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  1. #1

    Default Aluminium Lower Unit Repair

    Here is a little repair for my Aluminium Friends

    The Customer brought this puppy into the shop for a quick repair

    I get the fins from Mercury Performance out of Florida. You would think they would be finished better for what they charge but the unit is a little rough when received.

    The Customer is a true crusader on abuse of a product to its full potential.

    Welded with my Signature Series DX 300 (thanks to Kevin (KB FAB)for a great unit)

    At least he gave me the lower unit minus the BOAT

    A question for the Forum- I was told the Yamaha motors and the Hondas have a different Aluminium blend and cannot be welded. Something to do with a mixture of Magnesium in the Aluminum.
    Anyone know the truth on this?
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  2. #2
    Join Date
    Dec 2005
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    wisconsin
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    836

    Default

    Quote Originally Posted by LA Weld View Post
    Here is a little repair for my Aluminium Friends

    The Customer brought this puppy into the shop for a quick repair

    I get the fins from Mercury Performance out of Florida. You would think they would be finished better for what they charge but the unit is a little rough when received.

    The Customer is a true crusader on abuse of a product to its full potential.

    Welded with my Signature Series DX 300 (thanks to Kevin (KB FAB)for a great unit)

    At least he gave me the lower unit minus the BOAT

    A question for the Forum- I was told the Yamaha motors and the Hondas have a different Aluminium blend and cannot be welded. Something to do with a mixture of Magnesium in the Aluminum.
    Anyone know the truth on this?
    Its not magnesium, its copper. And yes it can be welded. However I personally think any Yamaha or Honda should be scrapped anyway
    If you want to weld on their castings use 4145 filler, preheat as you would normally for a cast material. Its nothing special, just cheap.
    "Better Metalworking Through Research"

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  3. #3
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    Default

    However I personally think any Yamaha or Honda should be scrapped anyway

    I'll agree with you on the honda they arent worth a **** but I wouldn't use any motor but a yamaha. Not trying to offend you just curious to your reasons for the dislike of yamaha. I trust my life to them on my offshore rig we run 60 plus miles out. I have also had the mercury outboard which caught on fire 18 miles offshore. My duck duck hunting rig and small privateer center con also run yamaha and they are abuse to say the least.

  4. #4
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    Mar 2009
    Location
    Eastern North Carolina
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    Default

    However I personally think any Yamaha or Honda should be scrapped anyway

    I'll agree with you on the honda they arent worth a darn but I wouldn't use any motor but a yamaha. Not trying to offend you just curious to your reasons for the dislike of yamaha. I trust my life to them on my offshore rig we run 60 plus miles out. I have also had the mercury outboard which caught on fire 18 miles offshore. My duck duck hunting rig and small privateer center con also run yamaha and they are abuse to say the least.

    Why didn't my quote go inside the nice little blue box

  5. #5
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    Dec 2005
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    wisconsin
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    Quote Originally Posted by Agcadmin1 View Post
    However I personally think any Yamaha or Honda should be scrapped anyway

    I'll agree with you on the honda they arent worth a darn but I wouldn't use any motor but a yamaha. Not trying to offend you just curious to your reasons for the dislike of yamaha. I trust my life to them on my offshore rig we run 60 plus miles out. I have also had the mercury outboard which caught on fire 18 miles offshore. My duck duck hunting rig and small privateer center con also run yamaha and they are abuse to say the least.

    Why didn't my quote go inside the nice little blue box
    You didnt leave the command code. ( [/QUOTE] etc.).
    Anyway back to the outboards, the history of outboards is kind of interesting. How all the companies were connected, the business aggreements etc. Anyway the basis on my feelings towards yamaha is primarily from my experience when the company I work for bought their engines or powerheads. The alloys used in the castings arent nealy as good as others, the basic engine design is more automotive and lacks durability. The gearcases are probably the worst for durability. I really cant tell you specifics...not that I dont know, I just cant tell. BTW what merc was it that "caught fire"? What model and how long ago?
    "Better Metalworking Through Research"

    Miller Dynasty 300DX
    Miller Dynasty 200DX
    Miller Spectrum 375 extreme
    Miller Millermatic Passport

    Miller Spot Welder
    Motor-Guard stud welder

    Smith, Meco, Oxweld , Cronatron, Harris, Victor, National, Prest-o-weld, Prest-o-lite, Marquette, Century Aircraft, Craftsman, Goss, Uniweld, Purox, Linde, Eutectic, and Dillon welding torches from 1909 to Present. (58 total)

  6. #6
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    Lake of the Ozarks MO
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    Default

    Quote Originally Posted by Agcadmin1 View Post
    However I personally think any Yamaha or Honda should be scrapped anyway

    I'll agree with you on the honda they arent worth a darn but I wouldn't use any motor but a yamaha. Not trying to offend you just curious to your reasons for the dislike of yamaha. I trust my life to them on my offshore rig we run 60 plus miles out. I have also had the mercury outboard which caught on fire 18 miles offshore. My duck duck hunting rig and small privateer center con also run yamaha and they are abuse to say the least.

    Why didn't my quote go inside the nice little blue box


    Well knocking Yamaha and putting Mercury on a pedestal is sorta tongue in cheek anyhow when you consider how much old Merc outboard stuff was made by Yamaha in the first place. I'm sure Aaron knew this and was just trying to get a rise out of everyone.
    As for Yamaha I just hate their dealership program and the outrageous cost of their parts. I'm more of an Evinrude lover myself and am growing fonder of Suzuki.
    As for weldability.....they all weld fine. I think the old Evinrude/Johnsons have the worst castings of anyone tho hands down! (lots of voids)

    BTW, LA Weld, how much gap did you leave between your pieces? I usually go with somewhere around 1/4 to 3/16ths.

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  7. #7
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    wisconsin
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    Default

    Quote Originally Posted by FusionKing View Post
    Well knocking Yamaha and putting Mercury on a pedestal is sorta tongue in cheek anyhow when you consider how much old Merc outboard stuff was made by Yamaha in the first place. I'm sure Aaron knew this and was just trying to get a rise out of everyone.
    As for Yamaha I just hate their dealership program and the outrageous cost of their parts. I'm more of an Evinrude lover myself and am growing fonder of Suzuki.
    As for weldability.....they all weld fine. I think the old Evinrude/Johnsons have the worst castings of anyone tho hands down! (lots of voids)

    BTW, LA Weld, how much gap did you leave between your pieces? I usually go with somewhere around 1/4 to 3/16ths.

    FK,
    The only engines merc bought from yamaha were the early 9.9/15 , early 115 and early 225. In fact the 9.9/15 was a joint venture, with the powerheads actually built by merc FOR yamaha. There is more to the story then anyone outside of the companies knows. Anyway this is getting off topic
    "Better Metalworking Through Research"

    Miller Dynasty 300DX
    Miller Dynasty 200DX
    Miller Spectrum 375 extreme
    Miller Millermatic Passport

    Miller Spot Welder
    Motor-Guard stud welder

    Smith, Meco, Oxweld , Cronatron, Harris, Victor, National, Prest-o-weld, Prest-o-lite, Marquette, Century Aircraft, Craftsman, Goss, Uniweld, Purox, Linde, Eutectic, and Dillon welding torches from 1909 to Present. (58 total)

  8. #8
    Join Date
    Nov 2006
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    Lake of the Ozarks MO
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    Default

    Quote Originally Posted by Aerometalworker View Post
    FK,
    There is more to the story then anyone outside of the companies knows. Anyway this is getting off topic
    I know more about this subject than most folks...

    And I agree...way off topic

    www.facebook.com/outbackaluminumwelding
    Miller Dynasty 700...OH YEA BABY!!
    MM 350P...PULSE SPRAYIN' MONSTER
    Miller Dynasty 200 DX "Blue Lightning"

    Miller Bobcat 225 NT (what I began my present Biz with!)
    Miller 30-A Spoolgun
    Miller WC-115-A
    Miller Spectrum 300
    Miller 225 Thunderbolt (my first machine bought new 1980)
    SPEEDGLAS 9100XX

  9. #9

    Default

    I left a 1/8 gap with 45 degree bevel on both sides.

    This was a recommendation from Mercury Performance that provided the replacement piece.

    I did leave as much of the original structure, so I did not follow the recommendations to the letter. Mercury Performance wants you to cut down to the housing. I don't like that and feel it would guarantee a catastrophic failure if the lower unit was to be damaged again. My thinking is the machined part would rip the housing as to its material strength.
    The weakest link being the casting, so you can follow my thought.

    Craig, here is a coupon from many many years ago. It was a training piece I did when I finally felt I could do it. It reminds me of where I came from and the GOOD OLD DAYS PAST!
    I gotta say, I was way to full of it then. How owning your own and growing up has it drawbacks...

    Good luck, just be patient.
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  10. #10
    Join Date
    Mar 2009
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    Eastern North Carolina
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    The mercury I had catch on fire was a verado five years ago. Motor had 500 some hours on it. It had an electrical short somewhere in the motor I suppose
    did quite a bit of damage to the wiring harness and burnt the hood on the outboard up bad. As for the difference in the castings on the lowers of yamahas I have absolutely no idea what the specs are. i know there a great motors and very durable in my opinion. My regulator has 1500 hours on my four strokes with no problems.

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