TOPIC: Merc lower cowling issues

Three of the four bolts that hold my cowling to the back "shield" of the motor (for lack of the precise term) are rusted and broken. I bought some high-quality hardware for the one remaining bolt

What I'd really like to do is replace the cowling, but if I recall that means some serious work (like removing the powerhead). Can someone please confirm for me? I have a nice extra sitting around.

Alternately, any suggestions for getting those buggers out?

Thanks!

Dave

I'm not even going to say the words "easy-out" Dave, every time I've even looked at one lately I've broken it off!

MarkS wrote:

I'm not even going to say the words "easy-out" Dave, every time I've even looked at one lately I've broken it off!

LOL, sorry. I suppose I could try that and soak them in PB Blaster for a couple weeks first. I'd really like to switch though as the replacement I have is in much nicer shape

Looking at the corrosion and oxidation on your motor, I'll bet you break more than just those bolts trying to replace the lower pan. It could turn into a nightmare in short order...

If you have anything to grab onto, I'd soak it in PB-Blaster and heat up the cowling with a propane torch. Try to ease them out with vice-grips. If they're not accessible with vice-grips, then I'd just drill them out and retap the holes. They only hold the cowling support bracket in place, so getting them perfect isn't a huge issue...