ProMax Rebuild

[Merc 2.5]

Lookin good , just replied to ur text. It slipped by me. Mines on it's way to him now , good luck with rebuild , if u need sumthin holler at me

[rgsauger]

So is James taking work again?

[Hydrodreams]

So is James taking work again?

I think he still may on a limited bases. Shoot him a message and see. Good luck! I got the block this afternoon when I got home. Haven't had time to fool with it a lot. I did do the #1 cylinder ring gap and it was .019. Which I am very happy with!

[Hydrodreams]

Well rebuild has commenced once again. Had a hick-up on the way home. Though James had packed the block well my starter bracket was snapped off my block during shipping. I took it to a local shop for repair vs shipping the front half back, having James repair, and waiting all that time. The block looks great otherwise and all the ring gaps were .019-.021. James did a fantastic job on the oil drive cavity, repairing the bottom of the exhaust chest where it had cracked, and making it stronger than stock. I have installed four of of the six wrist pins in the pistons. Was a neat tedious process. I had purchased the wrist pin ring install tool. Which made the process a lot easier. I am waiting on two rods. I ended up culling out two of my originals. I am taking my time, cleaning everything very well, and counting everything at least twice. I made a checklist to follow and came up with a process using a plastic tub for each piston. Once complete I put them in a gallon ziplock bag in a big tube ready for install. I have carefully chased and cleaned all the threads in the block. Taking my time by threading in and out, cleaning, blowing, and oiling. If you have never chased threads before use extreme caution during this process. Today is block and front half clean up day...amongst other jobs that need be completed. Then I will start on crank install. It's lying in wait cleaned, oiled, and in a plastic tub. (What looks like debris on the crank are air bubbles in the oil. I had just oiled it down before the pic.) Ready to go with the new bottom bearing installed, the sealing rings lapped, and the sealing ring leading edges slightly beveled. Top cap and bottom caps complete with seals, upper bearing, are ready for install. (The oven trick worked great!) JSRE heads look great and are ready for install. All in all, as you can see, I am taking my time, cleaning, counting, prepping, and using the heck out of ziplock baggies and Dollar Store plastic containers!

[Merc 2.5]

Sweet. looking good. Did u find 2 rods?

[Hydrodreams]

Sweet. looking good. Did u find 2 rods?

Yes sir, thanks Merc! Should be here middle of the week. Block is cleaned and ready to go!

[Hydrodreams]

I have had a few SNAFU's throughout this rebuild. They remind me to take my time and double check everything. I started the crank install Monday afternoon. I always look over parts when I get them. Yet I do not take them out of the bags until I am ready to install to keep them clean. Well I popped one of my mid main crank bearings out of the bag. I noticed the ring holding the races together wasn't tight against the outer race. My initial thought was to bend it back and move on. As I thought it's just to hold the races together during assembly. I decided to take a closer look not knowing the extent of the ring's purpose while under a load during operation. When I did I noticed a tiny nick in the ring itself. Along with some tiny imperfections on the race itself. So tiny I couldn't get a clear picture of them to post. I called ProMarine and they were quick to send me a new one. They even sent it Second Day Air because of my inconvenience. All that being said. the new bearing arrived and crank install went well. I had both halves together last night and snugged down. The crank rotated smooth as silk. The pistons I have ready will go in this weekend. My two rods got held up in shipping but are scheduled to be here Monday. Still cleaning, cleaning, cleaning, and double checking everything. On another note, I scored on a nice Alien cowl set! Whoop Whoop!

[Hydrodreams]

Well the ole ProMax is slowly coming back together. The block is buttoned up and torqued down. She spins smooth as silk. It's neat to see all the parts, research, and choices I have made come together. Cannot wait to hear her run again! I also shined up and put some new decals on the Alien cowl to go with the GS.

[Hydrodreams]

Harness is pretty much hooked back up. Have a few odds and ends to wrap up and the ACU to put on. My only dilemma is the old VST wires and the Water Separator Warning Box. Since I deleted the VST and went with a remote fuel pump. Can all of these wires just dead end and due away with the box? Or will that cause an issue somewhere else?

[Merc 2.5]

I dnt really know haha. But seems like u could dead end em , just make sure any hots r taped up or sumthin. Sumone else b along shortly that's done this

[Hydrodreams]

I dnt really know haha. But seems like u could dead end em , just make sure any hots r taped up or sumthin. Sumone else b along shortly that's done this

Thanks Merc Tux974 helped me out. Getting a little closer...

[Merc 2.5]

Shoot. Wont b long now. lookin good tho

[Hydrodreams]

Well the ProMax rebuild is complete! It was quite the process and learning experience but well worth the effort! I have put 6-1/2 hours on her thus far. The first five were all under 3500 RPM varying all the time and short bursts. I am in the 4500 RPM range now still varying and short bursts. All the while running 25 to 1 premix old school 2 Stroke dino oil. Nary a mosquito in sight! She is running as smooth as a top with no real issues at all. Getting stronger and more snappy all the time. I would like to thank the following users on S&F...Merc 2.5, Jay Smith, Go Time, Ace, tux974, W2F A Vking, Capt.Insane-O, tlwjkw, XstreamVking, luv2gofast, Wrenchn (James Perry), and last but not least pkstv (Thanks Mr. Paul!). You guys all helped me so much with advice, pics, text messages, and parts. Also anyone that helped out along the way. Especially with that fuel pump wiring! Ugh! (See my other thread) Thanks again y'all! I encourage anyone with mechanical ability to do a rebuild if you are in need, have the desire, and time. If not just send it to Mr. Jay Smith and I believe you will receive an awesome rebuild. I HOPE everyone has a safe enjoyable summer on the water! Let the fun begin!!!

[tnelsmn]

Nice job on completing the rebuild yourself. Thats a beautiful rig!

[Hydrodreams]

Nice job on completing the rebuild yourself. Thats a beautiful rig!

Thanks man, I appreciate it!