Check Out This Lower Unit!

[Greg G]

I had a Merc lower unit sitting for a year. It had developed a really tiny pinhole that would dribble out water on the very top of the cavity. When we carefully peeled back a bit around the "tiny" hole this is what we found in the picture below. This case was evidently done by one of the well known gear case guys who added a lwp cone. So much for that! Can we carefully stop/start weld this area with the proper stick to close it up (doing the work upside down) or would an epoxy be a better solution? The cleaned out area looks like all metal but it is hard to tell what is under the paint just beyond the area.

Anybody been through this?

[CNC_Guy]

Is that the upper edge of the cone? Looks like part of the hole where a hose could connect for dual water lines? I would take a small burr and explore a little more before welding to make sure filler material is far enough away. You would want a properly prepped surface for epoxy putty anyway. You could talk to Chaz too.
Dave

[Greg G]

It's at the very top of the case. Here is a picture of it before we started to explore the area.

[merc326]

Yea, that looks like where they used a dual inlet cone and just welded up that side. And like it was already said , you can either weld it or use epoxy. Both will work just fine.

[Go Time]

Greg, can you still see any threads inside the hole?

[Greg G]

Greg, can you still see any threads inside the hole?

Nope, no threads are visible in there. We are thinking that welding it is the best way to go. I'm not sure why this would have happened at all in this location. I may just leave it a bit proud so that if I sell the case the buyer knows what they are getting up there.

[perfmarine1]

If there is any epoxy/body filler in the area and you try to weld it will pop the filler. You may want to rethink welding it. Just MO

[David - WI]

I think I would drill & tap it for a hex pipe plug rather than burn any filler & paint around it off by welding on it?

[Greg G]

Thanks for all the info. We decided to go with welding. I will post a picture. Did not pop any filler and the weld seemed to take very nicely. Have to finish sand it and paint it now.

[Greg G]

Picked it up today. Here is a picture of the final weld. I have to emery it smooth and then paint.

[phillnjack]

Looks like you done a nice job there.
good job you noticed it when you did or could of ended up with a fried motor.
I think I would be checking all around that lwp to make sure no other bodge up were done.