First Rebuild 84 100 hp evinrude

[edfishing]

Guys,
I am in the middle of first rebuild. I have the crank installed and waiting to get the replacement (new one was broken) oring spagetti seal to close up the powerhead.
15-1/2 Jason bass boat. Not wanting to scream and fly just want it to idle better and run for a few more years.
1. New fuel pump kit was oversized (superseeded h*ll). My pump has steps at the top of the roof. Small crack (barely visable) in main plastic body. Anyone have middle section not cracked? Is this crack common?
2. Reeds can you just lap the cages and flip the standard ss reeds over? The stock reeds have slight wear around nose. Looking at CC reeds also.
3. Intake what are common "grinding" areas to do to the manifold? Lots of "flashing" on inside at parting lines.
4. I will do the break in on 25 to one oil and get an hourmeter installed to keep track of hours.
FYI it takes some time to get all of the dark blue paint off manually to reveal the metallic blue underneath.
Anything I should watch out for during final assembly?

Thanks

[ChrisCarsonMarine]

There are lots of small areas to clean up before assembly,but it sounds like the motor is almost back together already.Yes the intake can use some cleaning up,so could the whole back half of the block.When you say "rebuild"exactly what have you done?Don't flip the reeds over,they are way more likely to break if you do...the glass ones will run better,chris

[edfishing]

Bored and honed all four cylinders and polished crank. Relieved btm aluminum below sleeve because of different expansion rates. Hand worked with small round stone edges of ports for break of sharp edges. New bearings on lower&mid crank and connecting rods. 4 new pistons/wristpins. New carb kits, checked all the jet sizes (they are over .003-.004 from stamped number).
Spot faced one piston until it weighed same as other 3 (one is .064 over other three are .044 over)
Will post some before and after photos later.

[edfishing]

The chris carson reeds are twisted and will not lay flat even on lapped faces of cages. I will give them a day or two to straighten out but think the zip ties used in shipping were way too tight or these were stored in an hot area.

[ChrisCarsonMarine]

Ed,this is certainly an unusual situation,but if they don't flatten out after being attached to the cages we'll be happy to replace them...and I'll lighten up on the ties a little,Chris

[edfishing]

Thanks for the excellent service.

[ChrisCarsonMarine]

Ed,your welcome,sorry you had an issue,the reeds are on their way.Our goal is to provide top quality parts and service,Chris...BTW...your report of warpage is the 2nd in several hundred sets installed,and I'll start tying the reeds more loosely,thanks for bringing it to my attention.The first set flattened out after mounting.

[edfishing]

I got the second set in and installed Friday night and let them set until an hour ago. This set also does not set flat. Both sets are packed to be returned. If you look down the end each finger looks slightly twisted when mounted. The entire part looks slightly curled and I don't understand it. Even before I cut the looser zip tie these look twisted. I don't know but I give up. Thanks much for the customer support. I think USPS is XRAYing them and they are warping or something. I assure you these cages are dead flat and I am not crushing them with the screws. I think the items should be flat to start with and if you put them on a surface plate straight out of the box they should not rock and I did try to let them flatten out but they did not. I see at least .010 to .020 gap down the side of multiple fingers of the reeds.

[ChrisCarsonMarine]

Send me the cages and I'll install the reeds and send them back pronto,not sure what's going on but I'll get it straightened out,if your in a time crunch call me tomorrow and I'll send a set on cages to you and you can send me your trade-ins,Chris-305-394-3354

[ChrisCarsonMarine]

Ed,haven't heard from you,give a call please so we can figure this out,Chris

[edfishing]

I have returned both sets of reeds. You should get them in the mail in a day or two if you haven't already. I put both both sets in the same clam shell package without a zip tie.

[ChrisCarsonMarine]

Ed,would you like me to install a set of reeds on cages and send them to you,and you can send me your cages in trade?Sorry you had trouble but I'll help at no charge if you like...call or pm me,chris