Outboard Cover Fix

[Piddle and Futz]

This is still a work in progress, but thought it might be of interest to others...

When purchased, the cover of our Evinrude 50 had a large hole in the top cover. (There was even a wasp nest in there, one of about 50 in our rig. )


I was able to find some of the pieces and, after working out the jigsaw puzzle, glued them back together with primer and superglue specific for PBT plastic.


Then filled the missing gaps with plastic epoxy, generously applied to avoid any low spots.


Sanded it down to smooth using 120, 240, 360 grit (dry). Didn't go any finer than that as I want to have something for the spray paint to adhere to.


Next steps:

• mask off the 1 remaining decal
• spray a couple coats of primer/gap sealer (sanding in between)
• spray with matched Evinrude color
• either print or vinyl cut some new decals? (honestly not really a priority for me)
• wax and polish

Will post pics from next steps as the project continues.

There were a few cracks and broken bolts in the lower 2 cover halves that I also repaired and plan to paint. Just didn't show them here.

[Be Free]

If you want it really pretty: https://www.replacementdecals.com/store ... ecals.aspx

[Jimmyt]

Nice job! Can't wait to see the finished product!

[Piddle and Futz]

Well, I failed to take interim state photos, but after wet sanding with 800 grid, 2 coats of "Evinrude blue" spray paint, and a little polishing, here it back on the engine.



You will note that it doesn't perfectly match the lower motor housing, so looks like I will be painting that soon.

Far from perfect, but somewhat better than with a hole in it.

Also happy to report that I was able to revive that motor. Don't think it had been run in perhaps a decade. Took my time with the SeaFoam, turning it by hand to ensure the pistons weren't frozen, replaced all the fluids, new battery... patience and prayers. Relieved that it runs nice and smooth.

[Jimmyt]

Looks way better! Nice work! I know the wasps will appreciate their newly renovated home.