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  1. #1
    Join Date
    Oct 2010
    New Orleans/Northern California

    Default Outboard engine repair - lower unit

    This looks like a fun repair, huh?

    It is my buddy's lower unit on a boat he just picked up. The engine has just been rebuilt and purrs like a kitten, but there is some damage to the lower unit that I have been elected by unanimous vote to try and repair.

    Unfortunately, I forgot to take a picture before I started to clean up someone else's FIRST attempt at welding this some time ago (which didn't hold at all). I think the culprit might be the guy below because it looked a whole lot like pigeon $hit!! haha

    Having said that, I might not do much better! I am working with a Millermatic 211 and a Spoolmate. Wish me luck!

    (No doubt, I have a feeling my work will be ground flat and painted.)

  2. #2
    Join Date
    Aug 2008
    Orange, TX


    I picked up where someone else left off on one of these. They hadn't properly cleaned the material at the joint and was also missing a small piece. I should have cut it off and fit a new solid piece in and shaped as needed after welded. Would have been much easier and quicker in the long run.
    MM200 w/spot controller and Spoolmatic 1
    Syncrowave 180 SD
    Bobcat 225G Plus LPG/NG w/14-pin*
    *Homemade Suitcase Wire Feeder
    *WC-1S & Spoolmatic 1
    PakMaster 100XL
    Marquette "Star Jet" 21-110

  3. #3
    Join Date
    Jul 2008
    East Tennessee


    Dynasty 200DX "Blue Lightning"
    Bernard 3500ss water-cooler
    Rockwell vertical mill
    Beverly Shear B-3
    Beverly Shear JR
    Home-made English wheel
    Milwaukee Porta-band
    " Sawz-all
    Tennsmith 36" stomp shear
    Fixer upper 1968 Redface Lincoln sa200
    Powcon 300st

  4. #4
    Join Date
    Oct 2010
    New Orleans/Northern California


    Quote Originally Posted by Showdog75 View Post
    That's nice lookin' work!

    Here is my start before I have to shut it down for the night... go the wifey taking me out somewhere to eat for my birthday.

    It's not as pretty as you tig boys, but I think I can piece this back together. The biggest problem will be were the anode goes in place. That is a HUGE hole. There is an aftermarket cavitation (sp?) plate that bolts on, hence the holes. I wonder if I even need to fill in this hole. ?? I probably better. Maybe I'll cut a little jigsaw piece and weld it in place.

    Here is a shot of the first pass. Again, no nearly as pretty as a TIG weld!

  5. #5
    Join Date
    Sep 2005
    Salem ,Ohio


    I do some of those every summer. For the big holes i just lay it on a piece of clean steel and weld over it, instant patch...Bob
    Bob Wright, Grandson of Tee Nee Boat Trailer Founder
    Metal Master Fab Salem, Oh 44460
    Birthplace of the Silver & Deming Drill
    1999 MM185 w/185 Spoolgun,1986 Thunderbolt AC/DC
    Spool Gun conversion. How To Do It. Below.

  6. #6
    Join Date
    Oct 2004
    Edmonton, Alberta


    what the boat guys appear to do here is put a copper backing strip behind the repair (big hole) and with a spoolgun and preheat, weld to both sides of the crack till its gone then machine the unit to spec.

  7. #7
    Join Date
    Jan 2012
    Harrisburg, PA

    Default I've done many of these

    replacement Skegs can be bought. They are of the same grade aluminum as the lower units. Simply cut to match your repair area.

    Here's a link from one supplier:

  8. #8
    Join Date
    Aug 2010
    Los Angeles


    Quote Originally Posted by PA Weldor View Post
    replacement Skegs can be bought. They are of the same grade aluminum as the lower units. Simply cut to match your repair area.

    Here's a link from one supplier:
    that's. Great!
    Nothing welded, Nothing gained

    Miller Dynasty700DX
    3 ea. Miller Dynasty350DX
    Miller Dynasty200DX
    ThermalArc 400 GTSW
    MillerMatic200 with spoolgun
    Lincoln SP-170T
    Linde UCC305 (sold 2011)
    Hypertherm 1250
    Hypertherm 800
    PlasmaCam CNC cutter
    Fadal Toolroom CNC Mill
    SiberHegner CNC Mill
    2 ea. Bridgeport
    LeBlond 15" Lathe
    Haberle 18" Cold Saw
    Doringer 14" Cold Saw
    6 foot x 12 foot Mojave granite

  9. #9
    Join Date
    Aug 2004
    Milan Michigan


    Your weld is a little grainy which means your material is not very clean, I noticed that You still had a little paint on your preped pc.

    A grainy weld has contamination in it which makes it weak.

    Do a little better clean up prior to using filler metal and your weld will be shiny and good.

    I dont mean to bash you, Just constructive criticism.

  10. #10
    Join Date
    Nov 2010

    Default Outboard engine repair - lower unit

    Your welding cast aluminum with mig? What are you using for wire?

    That needs to be tig welded.
    Miller 350 LX Tigrunner
    Miller 350P w/XR-Pro
    Miller 250MP w/30A spool
    Miller 211 Autoset
    Hobart Tigwave 250
    Hobart Beta-Mig 251

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