The Cone heads

[Gmcviper]

I'm putting a come on my 200 gear case. The bottom of the cone seems too long is it normal to trim 1/2" off. plus the cone angle seems to be too far to be blended smoothly, picture atsched. There's a 1/4" gap on either side that the cone sitting further back would help fill. I just don't want to butcher this thing, then find out I messed up.

[Gmcviper]

Well I cut the 1/4" off and ground the inside of the cone about 3/8" deeper so it would fit better on the sides but there is still 3/16-1/8 gap.

[luv2gofast]

I did one several (many) years ago and cut and ground until I got the best fit then still had to bondo the crap out of it. Looking at the drain plug reminded me that I cut away room around that area, made a long stepped plug, oiled it so I could get it out and packed bondo around it. I also made a plug with a little clearance to the bondo but longer than the original so there was not a big cavity. I have seen several posts saying bondo cracks so don't use it but I had good luck and never had a crack. That boat is long gone so not sure how it's doing after 10 more years but I put about 10 hard years on it with no issues. I also made a plex template to shape both sides equal. I think I still have the template and maybe the bondo molding plug.

[Gmcviper]

I plan on using a shoulder bolt for a plug. Cut and contour it to match, use a hack saw to cut a slot in it. Good idea on the formed spreaders.

[outasite]

I plan on using a shoulder bolt for a plug. Cut and contour it to match, use a hack saw to cut a slot in it. Good idea on the formed spreaders.

Make your plug a little long,put it in tight with a new gasket,then mark it for a slot.That way when your done, the screwdriver slot will line up with the case and not cavitate and make bubbles along the side of the case.

[luv2gofast]

I plan on using a shoulder bolt for a plug. Cut and contour it to match, use a hack saw to cut a slot in it. Good idea on the formed spreaders.

You could probably wrap some tape around your Shoulder bolt plug to give you a small gap from the filler.

[Gmcviper]

The clown nose you order with the nose cone is a joke!