www.iFourWinns.com

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!

_________________
-Tony
2016 Robalo R200 w/Yahama 200!

Previous boats:
2003 Four Winns 248 Vista - sold
1994 Sunbird Corsair 200 - sold
1980 Checkmate Predictor - sold

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!

_________________
-Tony
2016 Robalo R200 w/Yahama 200!

Previous boats:
2003 Four Winns 248 Vista - sold
1994 Sunbird Corsair 200 - sold
1980 Checkmate Predictor - sold

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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Anything Worth Doing Is Worth Overdoing
2001 Horizon 180

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.

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!

_________________
-Tony
2016 Robalo R200 w/Yahama 200!

Previous boats:
2003 Four Winns 248 Vista - sold
1994 Sunbird Corsair 200 - sold
1980 Checkmate Predictor - sold

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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88 Four Winns 200 Horizon
4.3 OMC Cobra-4bbl
2002 Walker Bay 10/2012 Suzuki 2.5
2008 Walker Bay 8

1998 Jeep Grand Cherokee 4.0/Selectrac
2007 Jeep Grand Cherokee 5.7 Hemi/Quadradrive II

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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'96 200 Horizon 5.8l VP/SX

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!

_________________
-Tony
2016 Robalo R200 w/Yahama 200!

Previous boats:
2003 Four Winns 248 Vista - sold
1994 Sunbird Corsair 200 - sold
1980 Checkmate Predictor - sold