Can this sportjet 240 block be saved?

**Snoboarder** · 07-11-2019, 01:03 PM

Can this block be saved? Piston disintegrated rod punched out through side of block. Can it be welded and new sleeve installed or is it too far gone? If it can be repaired anyone have a good shop near eastern pa?

**JPEROG** · 07-11-2019, 01:09 PM

Chaz can weld and sleeve-hes fixed a lot worse. Next question is how many does he have in front of you.

Joe

**Snoboarder** · 07-11-2019, 01:21 PM

Thanks Joe, but my next question would have been who is Chaz?

**Merc 2.5** · 07-11-2019, 06:24 PM

A very very clever member here , machinist etc

**Snoboarder** · 04-01-2022, 10:13 PM

Finally getting around to doing something with this block. Im in PA, looking for someone who can take care of this block. Closer is better of course for shipping but want it done right so... if you guys can throw me some names and numbers of people who can handle it, would be awesome. Or if someone knows what block could be used to replace it, its second gen with the separate alternator. Thanks in advance.

**Merc 2.5** · 04-02-2022, 01:13 AM

Originally Posted by Snoboarder

Finally getting around to doing something with this block. Im in PA, looking for someone who can take care of this block. Closer is better of course for shipping but want it done right so... if you guys can throw me some names and numbers of people who can handle it, would be awesome. Or if someone knows what block could be used to replace it, its second gen with the separate alternator. Thanks in advance.

Is it goin back as a jet motor or turning it to a outboard?

**Snoboarder** · 04-02-2022, 06:24 AM

Jet

**Chaz** · 04-02-2022, 08:47 PM

Originally Posted by JPEROG

Chaz can weld and sleeve-hes fixed a lot worse. Next question is how many does he have in front of you.

Joe

Thank you J.P.

And yes you are right .. I'm not even taking in any more work until June or July.

**Dave S** · 04-03-2022, 01:18 AM

get a 2.5 150 block and port it ......Save ...... lots of $$$$$$

**Snoboarder** · 04-03-2022, 02:15 PM

Originally Posted by Dave S

get a 2.5 150 block and port it ......Save ...... lots of $$$$$$

Ok, what 2.5 150 motors came with the separate alternator? I already had bought a 2.5 motor for cheap, then realized it was useless because of different mounting standoffs and bolt holes. Researching is a PITA, why im asking for help from people with more knowledge.

**Chaz** · 04-03-2022, 02:51 PM

The jet engine

has different crank splines. so you will either need to use your crank or build a shaft with standard 2.5 splines.

280's came with alternator's. As did 3.0L engines. Simon Mototrsports had / has a kit to mount an alternator on a standard 2.5 block. Buying an alternator from mercury is ridiculous, they are $99.00 on flee-bay. You could have a local fabricator make / build / install any lugs / bosses / etc. that you will need .. start mocking up your new block .. tackle issues one at a time .. you'll see it will go pretty easy.

**Chaz** · 04-03-2022, 02:53 PM

Originally Posted by Merc 2.5

A very very clever member here , machinist etc

P.S. Thank ya Bobby ..

**Snoboarder** · 04-03-2022, 05:13 PM

If im going to all the trouble to have a fabricator add all the mounts i need, hope its right, port it to match and any other differences the 240 has, i might as well just fix the one i have! Not like im in a hurry. Im still exploring options so thank you, but id just rather have my block fixed or get a block that will work with minimal effort.
i also know about the splines, what i did not think about is the option of changing the jet side shaft to outboard splines. I could then mount a 200dfi powerhead. Just have to look at compatibility with boat wiring.
might be easier to just get on chas,s list, or if theres any other reputable shops that could handle block repair.