1986 21BR Cookie Monster - winter project

[JAA]

Hello all

I’ve decided that instead of learning to break boats, I’m going to focus on learning how to fix boats. This thread will detail my winter project.

Full disclosure, I’m a wannabe newbie boater. What I’ve learned is that I know nothing about boat ownership. So I’m here to be humble and learn. Please be patient and not surprised that I don’t know something .

This 21BR was purchased by the family about 10 years ago. It came with the name “Cookie Monster” (yes, I know the boat is red). We have done a poor job maintaining it mainly due to the fact my partners are cheapskates. Due to the recent failure outlined below, they are out and I’m the sole owner.

Pics of the boat:

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Pics of the "project" to come

[JAA]

My family had no idea there was oil in the outdrive unit. Yes, you heard that right. In the entire time owning this boat I don’t ever remember once checking or draining/filling the outdrive oil.

For a while now we have been hearing what sounded like a grinding when going into gear. Our guesses were shifter cable. This season the boat went kerplunk. Now when trying to put it in gear the boat would stall. Sounds like a safety switch right? That’s what we all thought. Though I went through the entire gambit trying to troubleshoot it and it all seemed to be operating properly. We ended up towing it and pulling it out of the water for winter storage. I convinced the family of cheapskates to let somebody look at it.

Took me forever to find anyone to look at the boat. This is CNY Oneida Lake so I figured I could find a bunch. Well, no one wants to touch OMCs. Finally found 1 place, after calling a half dozen who would check it out. They pulled the gear housing cover and I’m guessing you can figure what they saw (pics below). Yea - no drainage of oil necessary.

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[JAA]

I decided I wanted to keep the boat because I love it. It’s exactly the type of boat I want, more wood less fiberglass and the deep v hull works amazing on Oneida lake which can get very rough.

Saw the prices online for used outdrives and was very worried. Turns out my boat guy was able to come across a used outdrive for $1200. He says he will stand behind the unit. I go this route.

What I also did was keep my old unit ($300 core ) and have ear marked it as my winter project. I mean, what else do I have to do this winter except rebuild a 35 year old outdrive?

In all seriousness if I’m going to keep this boat, I better learn this stuff quickly. I also understand that the rebuild parts are not cheap at all. That said, I like spinning wrenches, so this will be a fun, and uncomfortably expensive, project.

Final pics of outdrive

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[JAA]

Ok - this is day 1.

My plan is to separate the upper and lower. From there, disassemble the upper and review the gears, check inside, etc. There is a good YT video on this. I’ll be taking pics along the way. You are welcome to heckle, but please also point out the obvious things I’m forgetting!

[JAA]

This is all that came out of the lower drain plug

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[JAA]

Note the relationship of the gear case index mark and trim tab grid so the two can be realigned later

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[Big Block Power]

Welcome and congrats. I'm here to watch this all winter. Oh yea it's a OMC!

[JAA]

Trim tab screw is a bear. I gave it a couple quarter turns and will let it cool. Any advice here?

[JAA]

I’ve snapped so many bolts I got scared.

Looks ok, will cleanup before reassembly (fingers crossed)

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[JAA]

If I thought the trim tab screw was bad, screws D and E are worse! Even more frustrating is I can’t easily get my impact wrench under there. Maybe I need to life the unit onto a higher platform

[JAA]

Full blast to get D to start turning!

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[dustinm]

The best of luck on this mission. Your tale of co-ownership is one of common occurrence, it will be much easier with sole ownership.

With the broken off bolts I like to weld a nut or if it is at or below the surface first weld a washer then nut to the broken bolt. Let it cool and then most of the time they will unscrew. I have had to repeat the process if I didnt get a good weld or sufficient heat soak. Last resort for me is to drill them out.

[rabiddawg]

Awesome, this gone be fun. Especially since I have my out drive off for bellows, gimbal bearing bushings seals etc.

I only broke one ground strap bolt!

Good luck and you have come to the right place

[JAA]

The best of luck on this mission. Your tale of co-ownership is one of common occurrence, it will be much easier with sole ownership.

With the broken off bolts I like to weld a nut or if it is at or below the surface first weld a washer then nut to the broken bolt. Let it cool and then most of the time they will unscrew. I have had to repeat the process if I didnt get a good weld or sufficient heat soak. Last resort for me is to drill them out.

Wait - so I have to learn how to weld too???

I’ve had luck with this:

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Thanks though, gonna need all the help I can get!

[JAA]

Awesome, this gone be fun. Especially since I have my out drive off for bellows, gimbal bearing bushings seals etc.

I only broke one ground strap bolt!

Good luck and you have come to the right place

Thanks!