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| Author: | taz42169 [ Tue May 01, 2012 10:04 am ] |
| Post subject: | Cracked Upper Gear Case Housing |
Hey all, During the course of sanding and prepping my outdrive, I noticed a nice sized crack in my upper gear case housing. Starboard side right below the second mounting nut. Anyone know of a good website or salvage place to buy a replacement (not at VP prices)? VP 3818650 Thanks and when you take three steps forward, you end up taking four backwards! 
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| Author: | taz42169 [ Tue May 01, 2012 10:10 am ] |
| Post subject: | Re: Cracked Upper Gear Case Housing |
P.S. A local marine mechanic said I could drill a small hole at the end of the crack to stop it from running and fill it with 5 minute epoxy... Not sure that is smart! Just thought I'd throw that out there! 
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| Author: | SeriousRob [ Tue May 01, 2012 12:03 pm ] |
| Post subject: | Re: Cracked Upper Gear Case Housing |
That would work if the area is not structural. Drilling the hole creates a larger surface area to spread the load and reduces the probability that the crack will spread. Filling with JB weld should create a watertight seal if you can inject it into the crack. This technique is used in aerospace applications of a non structural members. Rob |
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| Author: | Graham R [ Tue May 01, 2012 12:13 pm ] |
| Post subject: | Re: Cracked Upper Gear Case Housing |
if you get a new or second hand housing and try to build your gears into it, there's a lot of measuring and shimming required. In the area you indicate, the wall thickness is about 1/4". There's nothing behind it ( except a void that will be filled by water when the boat's afloat). I repaired a hole in the pivot housing on mine (resulting from a moment's inattention when trimming the drive up !) about 3 years ago, with "Chemical metal", a product designed to repair metal parts There's no sign of deterioration or cracking at the filer/ casting interface, the hole was pretty big. I could get to both sides of the hole, so it's well keyed in and locked in position. Depending on how severe/ long the crack is, my guess would be it's OK to fill it ( opened out on the outside and preferably on the inside) and the crack stopper hole with a metal repair paste. If it's close to the internal section where the driveshaft goes up to the gears, I'd be a bit more wary. |
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| Author: | taz42169 [ Tue May 01, 2012 12:55 pm ] |
| Post subject: | Re: Cracked Upper Gear Case Housing |
Thanks all, I spoke with another mechanic who confirmed the void in the area and the suggestion the other mechanic made is valid. I'll be drillling and filling later this week. Just a bit more reaffirming to hear the other mechanic didn't hit his head on a swim platform! 
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| Author: | LouC [ Tue May 01, 2012 7:18 pm ] |
| Post subject: | Re: Cracked Upper Gear Case Housing |
If that's the spot I'm thinking of, there is a slot there that is supposed to let water out that might get clogged and then the water expands when it freezes and cracks the end of the upper unit. I have seen pix of it on the net before. I'd consider that fix mentioned, or maybe it can be welded the way lower units are welded for repair. It would be expensive to replace the upper unit just for that damage. |
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| Author: | fiznuka [ Tue May 01, 2012 7:32 pm ] |
| Post subject: | Re: Cracked Upper Gear Case Housing |
Find a good fab shop and have them weld it. Don't JB weld-it because its not going to hold. There is nothing worse than trying to clean JB weld out of a crack that should have been welded the first time. Ask anyone who welds aluminum they'll tell ya. The cleaner the crack is the better weld you will get. |
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| Author: | taz42169 [ Wed May 02, 2012 6:04 pm ] |
| Post subject: | Re: Cracked Upper Gear Case Housing |
After much trouble shooting, the drain was in deed clogged! I cleaned it and, drilled another hole to make sure there was no remaining water in the cavity and had it welded! Dodged that bullet! Outdrive prep has re-initiated!
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