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  1. #1741
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    ...In the Mercury Castings Facility, large bins containing tin, copper, zinc & aluminum are mixed. These materials are the components used to create MercAlloy...

  2. #1742
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    Melting Furnace...The raw materials & scrap metal are heated to prepare them for the holding furnaces...

  3. #1743
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    ...Lost Foam Control Station...Most engine blocks Mercury produces start out as a foam template, stamped with a unique engine serial number, that stays with the engine the rest of its life. The ceramic coated foam pattern is placed in a crucible, that is filled with sand and then compacted...

  4. #1744
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    ...Lost Foam Pour...Using "Lost Foam Casting" to produce intricate single piece engine parts isn't new. But Mercury Marine put a new spin on improving the manufacturing technology to optimize its outboard technology & quality. In this process, molten metal is poured from a holding furnace through a Sprue. The molten metal melts the foam & assumes its shape, replacing it with the Mercury proprietary aluminum alloy...

  5. #1745
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    ...Engine Block Machining...This Mazak Machining Cell machines Verado in-line 4 cylinder & in-line 6 cylinder blocks along with their bedplates. The blocks are machined in stages - Premachining...Qualifying Machining...and Assembly Machining. These different stages require the block to be unloaded and loaded onto different fixtures, to allow certain features to be machined.

  6. #1746
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    ...Machining...Robots aid certain machining steps for processing and transportation of parts from one operation to another. This robot moves the blocks from a line-bore machine to a washer...

  7. #1747
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    ...EDP Paint Line...The powerhead components for Mercury Outboards and MerCruiser engines travel along a conveyer through Electodeposition Paint booths(EDP). This is an important step in Mercury's corrosion protection process. The powderpaint topcoat is harder, thicker and tougher, than conventional paint. In the final step, the components are cured in an infrared oven...

  8. #1748
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    ...Assembly...Robots assist in the assembly of Mercury Outboards in the 75 through 115 horsepower range. At this station, the robot torques the bedplate to the engine block, which holds the crankshaft, connecting rods, and pistons in place...

  9. #1749
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    ...Assembly...Eventually engine blocks are married to other engine components on the assembly line. The engine block travels from one station to another while assemblers attach the correct components at the correct time. Accuracy and quality are key in this process...

  10. #1750
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    ...Testing...Once engines are assembled, they are rigorously tested in a series of quality checks before being boxed & ready for delivery...

  11. #1751
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    ...The Finished Product...In the final stages of process, Mercury engines are cleaned & ready to be boxed - As a final step, they are placed in a sturdy container to await a customer order...

  12. #1752
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    ...MerCruiser Assembly...Mercury/MerCruiser sterndrive engines are assembled differently than outboard products. These engines travel through the assembly process on pallets, moving from station to station. The assemblers work instruction is listed on a touch panel in the workstation, telling the assembler the procedure to perform. When the work element is complete, it is checked off on the touch screen, allowing the engine to move forward...

  13. #1753
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    Would be so cool to do a engine plant tour in person.

    Dave
    1980 Cougar 19 tunnel,90 2.4L Bridgeport EFI in middle of restoration.
    1988 BAJA Sunsport 186, 96 225 Pro Max
    79 12' Auminum, 95 Merc 9.9
    RIP Stu
    "So many idiots, so few bullets"

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  15. #1754
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    ...MerCruiser Testing...As a final stage for sterndrives, MerCruiser engines are placed in a test room and connected to a diagnostic computer. This computer runs a series of tests to ensure the quality of the product before being boxed and ready for delivery...

  16. #1755
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    ...Don't forget to click on the bars at the top of each photo, to view the full sizing of each photo...

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