Boat Restoration and Repair

Doing boat restoration has become an ongoing hobby for me. Each project seems to be more complex than the last. I like that progression. It broadens my skill sets and prepares me for the next, which may be more difficult.

2005 Sea Boss Restoration

My last boat restoration involved a lot of wiring projects. I added a nice  sound system with a high power amp. I didn’t need to but I really wanted to make this boat stand out. To that end, I also added blue led interior lighting to it. In order to do that I had to add a lot of auxiliary wiring as well as switches and power panels. I also learned to leave drag string inside the hull for future wiring projects. I also learned a lot about fiberglass repair and gel coating. There was a large gash in the upper part if the boat. Thankfully, not in the hull.

Wahoo 18 CC Restoration

Before that I restored a Wahoo center console 180. That was really an education for me. I re-pwoered that boat with a used Mercury engine. It originally had an Evinrude. I learned the hard way that I had to run all new controls on that boat to match the engine. Here’s a link to that article. Wahoo Restoration

1966 Boston Whaler 13 Restoration

I’m on my third restoration project, a 1966 Boston Whaler 13. This one is going to be a challenge. The hull is in great condition. However, the inside shell needs a lot of work. There’s several layers of old paint as well as some fiberglass de-lamination that needs to be corrected. Not only that, but there are sections of the non-skid flooring that need to be repaired (ore entirely removed). On top of that, the engine, a 1988 Johnson 40HP hasn’t been run in over 20 years. I’ll be spending  a lot of time getting this seaworthy but am looking forward to the challenge!

Cleaning Fixed Idle Jet Passage on an Outboard Carburetor

Sealed Carburetor Access Ports

After rebuilding these carburetors I still had a rough idle. I took the carbs back off and removed the access plug and carburetor lead shot to clean the idle circuit out completely. I also found a good alternative to the expensive “carburetor lead shot plug” from OMC Johnson/Evinrude. This is my second go around with …

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How to Replace an Outboard Thermostat

New Thermostat, washer and Relief Valve Grommet

So far I’ve done a number of things to restore this old outboard to life. Before going any further though, I want to make sure there is adequate cooling for this engine. There are two things I’ll tackle to do this. First, I’ll replace the outboard thermostat. This engine hasn’t been in run on a …

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Make Your Own Spark Plug Wires DIY

Spark Plug Wires and MSD Crimp Tool

Making Your Own Spark Plug Wires Building your own spark plug wires is a simple yet rewarding task. They are not complex to build and do not require advanced skills. If you have worked with wire strippers and crimpers you can easily build your own spark plug wires. In this post I’ll be describing the …

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How To Accurately do an Outboard Compression Test

Compression Gauge

Why Compression Test an Outboard Engine There are several reasons you may want to compression test an outboard engine. If you notice the engine is running rough (especially at idle) is one. If you are buying a used boat than certainly performing a compression test is definitely in order.  Don’t make a decision on purchasing …

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How to Inspect Reed Valves on a Johnson 40hp Outboard

Removing the Manifold and Reeds

Reed Valve Inspection Now that I have I have the carburetors off the engine and on the bench, it’s a good time to pull the manifold and reeds off. I want to perform a reed valve inspection. If necessary, replace any components that are not up to par. The first step in this process is …

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1988 40HP Evinrude Johnson Carburetor Rebuild

Rebuilt Johnson Outboard Carburetor

My first attempt at starting the Johnson 40hp Engine resulted in a few sputters and a bang or two. Consequently, I checked the carbs and drained the one on top. My reward was a stream of prehistoric ooze. I tried removing the screw from the bottom carb to drain it as well, I found that …

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Evinrude 9.5hp Lower Unit Gearcase Rebuild – Part 3

9.5 Evinrude Lower Unit

Final Assembly So far I’ve gotten the unit torn down, the seals and bushings replaced and installed the shift rod and the impeller. Now it’s time to get on to the final assembly and testing. I’ll be focusing on the lower unit gearcase. Let’s get on with installing the gears, sealing the unit up and …

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Evinrude 9.5hp Lower Unit Impeller and Seals Rebuild – Part 2

9.5 Evinrude Lower Unit

In my last post, I described how I tore down the lower unit. In this post I’ll be re-assembling it. I’ll be taking the following steps to get it complete back together. Replace the seals, including the shift rod bushing and o-ring Re-install the lower unit impeller, plate and gasket Reassemble the drive gears seal …

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Evinrude 9.5hp Lower Unit Rebuild – Part 1

1971 9.5hp Evinrude on Back of Boston Whaler

Removing the Lower Unit Dropping the lower unit was fairly simple. There are four bolts holding it in place. There is also a shift rod connector that you have to take into account to completely release the lower unit. If you look at the  pictures below you can see the Brass connector on the far …

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How to Fix an Outboard Stuck Tilt Tube or Frozen Steering Rod

Johnson 40HP Stuck Tilt Tube and Frozen Steering Rod

The Boston Whaler 13 I purchased came with a 1988 Johnson 40hp outboard. We had to return to pick it up in the bed of my truck. Once we got the engine home my son and I removed it from the truck. We mounted it on the wooden stand I had built. That’s when we …

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