repairing a broken outboard lower cowling

[Yakdoc]

Hi All,

Just finished repair of a set of lower plastic cowlings for an outboard motor, they were held together by 10 lugs, 9 of which where broken, most in multiple pieces, plus to make it worse some bits where missing and it was covered in oil
The owner had been quoted $1200.00 for a new set, Ouch!!

7 cracks on this piece and the rhs bit is from the other cowl.

A jigsaw of mixed pieces, two different types of adhesive where used by the owner in an attempt to fix this, it all have to be removed before work could start.

this lug was missing a section of panel,

with no suitable donor material it was built up with weld

and then more weld

smoothed out with a dremel tool a good spray painter will make this all look pretty.

5 separate pieces on this one lug, I'm going to be real good at jigsaw puzzles now lol

after running a drill bit through the repaired lugs it bolted up together nicely

Cheers Yakdoc
http://www.yakdoc.com" onclick="window.open(this.href);return false;

[ratbag]

some great work there yakdoc!

[Yakdoc]

some great work there yakdoc!

Thanks ratbag, beer o'clock has soothed my savage nerves lol :Bar:

[smile0784]

i probably would of scrapped it and bought a new motor lol

[Nude up]

How did it break apart in the first place was it impact damage or the dreaded corrosion

[Yakdoc]

How did it break apart in the first place was it impact damage or the dreaded corrosion

G'day nudeup, seems its a fairly common problem from what I hear, reasonably new motors and the plastic breaks, I have a suspicion that oil and fuel swell the rubber liner between the cowls and put a lot of pressure on the plastic, add vibration and heat and something usually gives.

[Nude up]

Mate you did a great job of the repair as you said a good paint job nobody would know the difference

[tuna tube]

Fantastic job Yakdoc! You definitely deserve a beer after that effort. Not light beer like nude up :Bar:

[barra mick]

Thats is some awsome repair work there !! You are handy on the tools there yakdoc.

Clearly a well earned heavy beer was earnt , lucky your apprientance wasnt nude up or you well of been having a fluffy duck instead of that heavy beer

[gazza20014au]

outstanding repair job mate evinrudes are notorious for cracking the cowlings :doh1: they have a new style of outboard coming out in 2 weeks