5 Winter Projects

Show & Tell time! Photos, comments, stories, etc

5 Winter Projects

Postby 58woody » Thu Dec 06, 2018 4:30 am

We are working on 5 projects this winter:

1961 Merc 700 FGS Short x 2 - complete rebuild from the ground up
1961 Merc 500 - complete rebuild from the ground up
1956 Mark 30 - complete mechanical rebuild and lower unit rebuild and paint only
1959 Mark 55A - it was sunk, complete mechanical rebuild and lower unit repaint

It all starts here.

Using emery cloth, all journals are cleaned. Then I use strips of red Scotch Brite pads for a final clean finish. Washed and ready to build. This is the Mark 55A crank.

This thread will be stories from various components during this very busy winter build season.
Attachments
A07BE3DB-A487-43EC-ADB6-13E0295CA486.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby 58woody » Thu Dec 06, 2018 4:35 am

This is the madness I put upon myself.

Many parts have been cleaned, rebuilt but so much more to do.
Attachments
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Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby mark 55 » Thu Dec 06, 2018 4:48 am

Really looking forward to watching these builds Chris!! Thanks for sharing!
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Re: 5 Winter Projects

Postby 58woody » Thu Dec 06, 2018 5:00 am

I spent last winter tearing all my parts motors down. I have all parts organized and it so nice to just go and grab what ya need.

The Merc 500 rods are collected and ready for cleaning.
Attachments
7AEC1B1B-E669-429F-AFEB-99D99A48DAF5.jpeg
3243591E-B1E2-4BD0-BF37-F4F49942A23D.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby Kiekhaefer » Thu Dec 06, 2018 8:08 am

Cool. Glad you’re posting this. Looking forward to it.
John Stoltz

'59 Mark 35aE
'53 Mark 15
'60 Merc 400E
'61 Merc 700 FGS
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Re: 5 Winter Projects

Postby mercaholic » Thu Dec 06, 2018 2:06 pm

I had a tour of Chris' basement workshop and was really impressed how organized and clean it was.... :arrow:
Mississauga , ONT
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Re: 5 Winter Projects

Postby zul8tr » Thu Dec 06, 2018 2:55 pm

58woody wrote:We are working on 5 projects this winter:

1961 Merc 700 FGS Short x 2 - complete rebuild from the ground up
1961 Merc 500 - complete rebuild from the ground up
1956 Mark 30 - complete mechanical rebuild and lower unit rebuild and paint only
1959 Mark 55A - it was sunk, complete mechanical rebuild and lower unit repaint

It all starts here.

Using emery cloth, all journals are cleaned. Then I use strips of red scotch pad pads for a final clean finish. Washed and ready to build. This is the Mark 55A crank.

This thread will be stories from various components during this very busy winter build season.


Nice work icon_thumbup.gif  What grit grade emery cloth ?
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Re: 5 Winter Projects

Postby 58woody » Thu Dec 06, 2018 3:28 pm

I have been using 150 grit emery cloth on all my cranks.
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

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Re: 5 Winter Projects

Postby DaytonaJohn » Thu Dec 06, 2018 3:30 pm

I use crocus cloth on polished surfaces
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Re: 5 Winter Projects

Postby ctpdsr » Thu Dec 06, 2018 11:24 pm

A nice variety of models!

I have so much respect for guys that have the patience to disassemble and rebuild the service towers, suspensions, etc. I stick to everything north of the powerhead gasket.

Looking at the photos, the only minor suggestion I would make is to keep the pistons and original piston pins together as sets. A couple of guys have told me not to mix and match these over the years. The Master Service Manual also mentions that the pins are never sold separately because of "slight variations in sizes and correct "fit" into piston."


Chuck
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Re: 5 Winter Projects

Postby mercules » Thu Dec 06, 2018 11:45 pm

DaytonaJohn wrote:I use crocus cloth on polished surfaces

This is specified in my 1975 manual, I wonder why?
Let's fix it now - before we launch the boat.
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Re: 5 Winter Projects

Postby Yellowjacket » Fri Dec 07, 2018 12:23 am

ctpdsr wrote: Looking at the photos, the only minor suggestion I would make is to keep the pistons and original piston pins together as sets. A couple of guys have told me not to mix and match these over the years. The Master Service Manual also mentions that the pins are never sold separately because of "slight variations in sizes and correct "fit" into piston."


Chuck


Always!!!

mercules wrote:
DaytonaJohn wrote:I use crocus cloth on polished surfaces

This is specified in my 1975 manual, I wonder why?


Could be because it's best practice..  But the real reason is because it leaves a polished finish.  I've always used it on journals for just that reason...
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Re: 5 Winter Projects

Postby 58woody » Fri Dec 07, 2018 2:55 am

Other then the one pile of 700 parts, wrist pins are matched to their original pistons.
But in some cases they are not. I carefully check the wrist pins and if they are worn I chuck them.
I have 2 that need to be replaced on the 55A.

Here is my technique for painting the washers on the 700 and other mid shocks.
I use a spare tube for the shocks and a shock bolt and some tape to hold the washers and paint.
They were primed with self etching primer.
Attachments
9BE2EDCD-B141-4566-87CC-30B1C8C8D944.jpeg
AD65085B-D7FD-4010-94BE-9C0AD4D10904.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby 58woody » Wed Dec 12, 2018 4:11 am

5 blocks are ready for honing and washing.

There were some stubborn gaskets. I use my trusty scraper and box knife. Carb cleaner helps loosen stuck on gaskets. I use a file and wrap 180 grit paper to start prepping all sealing surfaces.

Next is honing 24 cylinders. Then I send them out for an industrial bath. One of the Merc 700 blocks has one broken stainless screw which my local shop will remove. They have a large block cleaner.
Attachments
CF47720E-6C91-4AA3-8531-64114C6B43EF.jpeg
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3B882023-5B0B-4D82-AD84-07011E9D9C99.jpeg
680181C6-7DCE-4F6C-9F45-F29BAB5B0333.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

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Re: 5 Winter Projects

Postby 58woody » Thu Dec 13, 2018 6:02 am

This is now getting into the fun part. Assembling one of the 1961 Merc 700 FGS shortie.
I ream out all holes where bolts or screws go because some paint builds up in them and during assembly they won’t fit.

The first step for me is putting one new nut on the tilt tube in my vice. I tape the nut not to scratch it.
I place an old one on it so when I go to add the other side I use a second wrench on the old one and causes no damage.

On we go...
Attachments
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2433F1F7-C875-446D-822C-0117DCB2720B.jpeg
E013F54A-C7C7-46B0-B2D1-8271AFD1A554.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby 208rooster » Thu Dec 13, 2018 3:49 pm

Looks great Chris I love watching your builds. Rick
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Re: 5 Winter Projects

Postby 58woody » Fri Dec 14, 2018 9:14 pm

All the upper and lower shock were taken apart, cleaned and a few parts replaced. The lower shock bolts hex head is alway rusty, so I clean it and paint. Once installed I put grease on the rubber cap that goes over the hex head. I always double check installation with my trusty manuals. I always put new packing cups on the upper shock covers.
Attachments
IMG_7608.JPG
IMG_7612.JPG
IMG_7613.JPG
IMG_7615.JPG
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby 58woody » Sat Dec 15, 2018 11:02 pm

The mid is now together. Assembling the bottom cowl and then can not wait to get the powerhead on.
Attachments
93ED3FC7-A0F6-4FD5-B36B-96114AB00CBC.jpeg
0C270019-48E5-4164-9018-6501BB02DC41.jpeg
9F5DE2D0-A441-4B3D-88F0-2743E2B54FE5.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby 58woody » Mon Dec 17, 2018 4:07 am

Bottom cowl is ready to install, just need to add the water tube.

Very excited to get the powerhead on.
Attachments
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BA35D330-3009-4CBE-B99A-F34793DCF24E.jpeg
679EB191-898D-4C05-BB1C-A1F0BB365802.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby Kiekhaefer » Mon Dec 17, 2018 10:05 am

Gorgeous :arrow:
John Stoltz

'59 Mark 35aE
'53 Mark 15
'60 Merc 400E
'61 Merc 700 FGS
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Re: 5 Winter Projects

Postby Four Sons » Mon Dec 17, 2018 6:50 pm

Wow,  very nice work!  Impressive.
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Re: 5 Winter Projects

Postby 58woody » Tue Dec 18, 2018 5:48 am

Bleed lines installed on the block and lastly the distributor linkage was taken apart and cleaned. I find these moving parts get a lot of hard grease build up and become very stiff. Sure you can lube it but after 60 years taking it apart and rebuilding it makes them operate very smoothly.

Block is going on the mid next!
Attachments
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24A9D769-FEE9-4AFF-93E5-BF108BB41B20.jpeg
9F280711-1ACB-4583-8123-1081AED0F051.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby 58woody » Mon Dec 31, 2018 2:21 am

I installed a 2000 lb ATV electric winch so I can install powerheads and lift completed motors off stands from the basement workshop. Works awesome.

I use sealant on both sides of the gaskets for the mid to bottom cowl and then for the powerhead.

Managed to get quite a few components on today.
Attachments
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Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby Kiekhaefer » Mon Dec 31, 2018 4:06 am

Chris, a few questions. What did you do for electrical wiring all new wire? What about the lead seal? How did you reattach it? Did you sent out your bolts/nut and parts for new gold zinc plating?
John Stoltz

'59 Mark 35aE
'53 Mark 15
'60 Merc 400E
'61 Merc 700 FGS
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Re: 5 Winter Projects

Postby 58woody » Mon Dec 31, 2018 4:15 am

I buy new zinc plated bolts at Brofasco or also know as Bolts and Nuts.

For this project I bought a refurbished wire harness from Todd Pulis, he does fabulous work for $110.
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

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Re: 5 Winter Projects

Postby 58woody » Mon Dec 31, 2018 6:22 am

It is called Bolts Plus, I get stainless wire harness bracket screws, crank case bolts, spark plug cover screws and all sorts of others.

I get lead seals from Joe Poole, the wire loops through a hole in the seal and you just squish it.

I will get a Mercury die made one day to stamp them with a logo.
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

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Re: 5 Winter Projects

Postby 58woody » Mon Dec 31, 2018 4:48 pm

I added a couple shots showing the resistors and coil hook ups for a 1961 Merc 700 FGS.

The blue choke wire that runs from the top cowl will connect where the blue wire is attached to the connector hub.

The short red jumper wire on the coils is the + positive posts.
Attachments
51D086DD-C7FC-4A7C-B0B3-2F3440C526A5.jpeg
422F6414-F846-484B-BA79-F5EB4B3E249C.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby 58woody » Mon Dec 31, 2018 10:58 pm

Made new distributor wires today.

I buy new terminals, solder the Packard 440 wire into them.
Always check the connections with your meter.

After each weld I pull on the wire to make sure it is strong, that’s why the nut is in the vice. It holds the terminal and for a strength test after.

I added some solder as well to the coil plug end.

A little Vaseline and the plug caps, numbers and coil ring holder slide on so easy.

The photos show my process, works great and I know these are solid connections.

The factory just crimped the wires on and they get damaged when they are screwed in and out of the distributor cap.
Attachments
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5ACD2909-61B7-47DB-AAA5-1DA258B83472.jpeg
C99FC17B-0243-4ABB-B8EB-43C6607303B5.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby Kiekhaefer » Tue Jan 01, 2019 9:26 am

Thanks Chris. I enjoy your posts. Beautiful work.
John Stoltz

'59 Mark 35aE
'53 Mark 15
'60 Merc 400E
'61 Merc 700 FGS
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Re: 5 Winter Projects

Postby 58woody » Wed Jan 02, 2019 2:30 am

Fuel system and distributor installed. Spark on all 6. On to the top cowl, a few finishing touches and then set spark advance.
Attachments
04507E8C-F2D1-4296-B0FF-E1AF6712D992.jpeg
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C0D2B034-CE42-4032-8095-1F39C5BDF30D.jpeg
0FDFF969-C583-470D-8B9B-335A0235EC71.jpeg
B7FB2093-B5FE-466B-8174-823C17B41B5B.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

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Re: 5 Winter Projects

Postby 58woody » Thu Jan 03, 2019 8:47 pm

Assembling the top cowl. I always check the threads and run a tap through them.
Here’s a trick to install and remove the threaded posts.
I always remove them when the cowl is blasted and primed.
Use a little loctite on the post thread, I place a fine lock nut on the post top and then add a second and tighten the 2 together. Now you can easily screw in the post, loosen the 2 nuts and off they come.

Handles are being chromed and bands polished.
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30012513-6300-48FC-A43B-D7894B9E96CB.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby ctpdsr » Thu Jan 03, 2019 9:29 pm

Beautiful work as always!

That is exactly the way I mount studs in the cowls & block. Your starter rope/handle weave is just the way they came from the factory. Here is a little variation on the rope routing that we developed over the years. May be worth a try? I like this style handle for race motors vs. the older knot version. Also use a small file to break any sharp edges in the casting that could saw the rope over time...

Chuck
DE976133-F3CC-470B-95EC-88506B6537C6.jpeg
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Re: 5 Winter Projects

Postby Pondrocket » Sat Jan 05, 2019 12:12 pm

Well done Chris !!!!

Travis
Mark30e,57'Mark55e,3-Mark58s's,Mark78ael,twin 64'Merc 650's Classic Mercs Keep em Alive! https://waterhogsworks.com/
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Re: 5 Winter Projects

Postby zul8tr » Sat Jan 05, 2019 4:13 pm

ctpdsr wrote:Beautiful work as always!

That is exactly the way I mount studs in the cowls & block. Your starter rope/handle weave is just the way they came from the factory. Here is a little variation on the rope routing that we developed over the years. May be worth a try? I like this style handle for race motors vs. the older knot version. Also use a small file to break any sharp edges in the casting that could saw the rope over time...

Chuck
The attachment DE976133-F3CC-470B-95EC-88506B6537C6.jpeg is no longer available


On my 25ss during race days I have done it both ways on the wrap and still had the post with the last wrap snap off on occasion icon_thumbdown.gif . It receives the most load from the rope pull since it exits direct to the recoil. Plus the 25ss with full lock on the timing makes for a terrible kick back that doesn't help that handle design, definitely need a safe process to start them. ). During the race days resorted to the simple double knot in the rope type handle, just black and no pretty Mercury name, the KISS approach. Now using that pretty handle since no 5 minute gun  :-) Suppose not an issue with engines having retarded mags to start them (30H, 55H, service engines).

Several years ago at an AOMCI meet had that post break on the 25  [swearing.gif] and not wanting to wast a casting that could be easily fixed and still wanted to keep that pretty grip so here is  my stronger fix with no degrade in the fit or look, once rubber grip slid back never know the bolt/nut is there [wrench.gif]. Used a counter sink bolt and a thin nut and ground off extra bolt length.
Attachments
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SW Orlando, Fla
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Re: 5 Winter Projects

Postby Four Sons » Sun Jan 06, 2019 12:56 am

Wow,  your attention to detail is impressive!  Thanks for sharing.  By the way, I happened to come across several of your YouTube videos of the 6 cylinder project... selfishly, I would encourage you to do more videos of your work.

Thanks, Pat
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Re: 5 Winter Projects

Postby 58woody » Wed Jan 09, 2019 5:21 am

Onto the Mark 55A crank assembly. All parts were cleaned, ultra sonic cleaned, honed surfaces and inspected all needle bearings, screws, reeds, complete go through.

Though this motor tragically got partially sunk there definitely was some parts that were failing.
Bearing carrier, rod and piston needle bearings all had edge damage starting.

After each rod assembled on the crank I take a small tool and just make sure I missed no needle bearings.

I made a little insert for putting wrist pins in the pistons, works perfect.

I use Lubriplate 105 grease.

All replaced and back together.

The first pic shows some needle bearing edge damage.
Attachments
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Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

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Re: 5 Winter Projects

Postby 58woody » Wed Jan 16, 2019 4:08 am

Mark 30 crank coming along...
Attachments
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29838CD8-9185-4E7E-BDEF-C85EBB7B30E1.jpeg
23120776-781A-4EBA-BD0C-1A6573C205D2.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby ctpdsr » Wed Jan 16, 2019 10:38 pm

Nice looking crank! Those old 400-2 small taper cranks are getting harder to find in decent shape.

Note for readers - see the bottom end bearing surface has about a 3/8" gap or recess at the very end. This calls for a single seal bottom bearing cap. Newer cranks had a 100% finished surface and double seal cap. The term "small taper" refers to the diameter of the top end where the flywheel mounts. Mercury enlarged this end and thus the flywheel openings in 1958 or so.


Chuck
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Re: 5 Winter Projects

Postby 58woody » Thu Jan 17, 2019 4:00 am

Used my new piston tool this evening. I like it. Great for also removing old pistons.

Mark 30 crank is now ready for the block.

Merc 500 crank next.
Attachments
3FE60745-F42F-46CA-BC85-FFDEB78BE63F.jpeg
EBE3E821-1BB4-4372-9715-FEB2114790E5.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby mercaholic » Thu Jan 17, 2019 2:27 pm

Thanks for sharing the rebuild.

I've adopted your technique for keeping the crank pins in place for installation.
Mississauga , ONT
Canada
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Re: 5 Winter Projects

Postby 58woody » Sat Jan 19, 2019 12:48 am

Evening Mark 30 assembly block assembly begins.
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71D2D852-5790-4954-A4B7-36EB83967934.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

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Re: 5 Winter Projects

Postby creekrunner » Sat Jan 19, 2019 1:34 am

Nice shop ! icon_thumbup.gif
Experience is a wonderful thing...........it enables you to recognize a mistake when you make it again.....
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Re: 5 Winter Projects

Postby 58woody » Sat Jan 19, 2019 4:30 am

Bought 15 NOS rings, much to my surprise 8 of the 15 rings are over sized.
Are .015 - .030 over sized Mark 30 rings sought after? I need to further measure them.

Just ordered 6 additional standard Mark 30 rings.
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

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Re: 5 Winter Projects

Postby Tom Brockmeyer » Sat Jan 19, 2019 6:10 pm

That piston pin tool is one of my own favorites!  First time I used it was on a Harley-Davidson 2-stroke golf cart engine.  It worked so slick I just sat there and smiled!  The fine threads on the driver rod made it feel like a hydraulic press was inserting the pin.

ANY CHANCE, 58Woody, that you could do a quick video that features the design, use, and operation of that tool..???

Tool is Part No. 91-28734    and maybe? 5443A1

Tom
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Re: 5 Winter Projects

Postby 58woody » Sat Jan 19, 2019 8:47 pm

Tom Brockmeyer wrote:That piston pin tool is one of my own favorites!  First time I used it was on a Harley-Davidson 2-stroke golf cart engine.  It worked so slick I just sat there and smiled!  The fine threads on the driver rod made it feel like a hydraulic press was inserting the pin.

ANY CHANCE, 58Woody, that you could do a quick video that features the design, use, and operation of that tool..???

Tool is Part No. 91-28734    and maybe? 5443A1

Tom


Will do, I have 2 more cranks to assemble.
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

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Re: 5 Winter Projects

Postby 58woody » Sat Jan 19, 2019 11:29 pm

Mark 55A crank installed, no issues with proper rings.

Check that your rings are springy in both sides of the block.

I brush a little 2-stroke oil on the cylinder tops.
It dropped right in.

Final block paint, in the coming days this one will be completed.
High heat aluminum finish.
Attachments
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63A6254C-E48F-4CB4-9276-33A7B00A73D0.jpeg
CF3EE436-2A42-41AF-8232-93C29F86F7AD.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

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Re: 5 Winter Projects

Postby 58woody » Sun Jan 20, 2019 11:00 pm

Merc 500 assembly started, needed to carefully dress the top rod journal.
Otherwise a nice vintage crank to start with.

Thanks Tom B for a chat about it.
Attachments
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B7897BD7-2A9B-421D-AAB8-E72DB6336602.jpeg
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EA935D0F-0AB0-4A76-AA24-C79A40A369C7.jpeg
A150D29F-81D4-43C6-8E53-6BBFCC190147.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby 58woody » Mon Jan 21, 2019 8:03 pm

Merc 500 crank built, next is my last one for these winter projects another 1961 Merc 700 FGS and a video of the piston tool in action. Is there any value in a complete crank assembly in a video?
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A085F206-8201-4D10-AD5A-35E19BD9771D.jpeg
Mark 6, 1956 Mark 55 & 55E, 1959 Mark 55A, 1958 Mark 58, 1960 Merc 300, 1961 Merc 500, 1961 Merc 700, 1964 Merc 1000 Bradford, Ontario, Canada

Member of the AOMCI Upper Canada Chapter http://uppercanadachapteroftheaomci.yolasite.com/
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Re: 5 Winter Projects

Postby mark 55 » Mon Jan 21, 2019 9:08 pm

YES!!! Absolutely!! Reading your comments and seeing pictures is great but a video showing the crank shaft assembly process from start to finish would be amazing! Even if it were a series of photos/narrative in order would be super helpful!

Great job on this thread! Demystifying power head building to a rookie like me for certain. Very much appreciated!!

Scott
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Re: 5 Winter Projects

Postby Four Sons » Mon Jan 21, 2019 9:56 pm

Oh yeah,  I'd like to see the crank assembly process.  All these process pictures (and a video would be even better) will help me muster the courage to rebuild a Mk55 I'm looking at buying!  Also, I just noticed... comparing the Mk30 crank (Jan. 16 post) to your last picture of the 500, do these pictures illustrate the difference between the so-called small taper crank and large taper?  

Thanks for your excellent posts.  

Pat
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