Rebuilding the 1965 Johnson 9.5

Initially purchased this motor, again on craigslist, for $100 as a parts motor.  Previous owner said it had no spark.  No gas tank or hose.  Hood had received a fantastic rattle-can silver upgrade in the past.  She had good compression, no leaks in the lower unit, and was mostly complete.  I did use a few minor parts to rebuild the 68 Evinrude, but changed my mind, and replaced them.  I them pulled the flywheel, replaced the coils, condensers, and points.  Used the coil locating ring and timing tool purchased from franksoutboardtools.  Very good reproductions of the OMC tools.  Was able to get spark.  Installed new plugs and was able to get her to run, again poorly with the choke wide open.  Cleaned and rebuilt the carburetor,  Was able to get her to run properly and idle very well.  Dropped the lower unit, changed the impeller, impeller wear plate, impeller housing and water tube seal.  Runs like a champ.  Next, I cant leave it with the horrible silver paint job.  Started sanding it off, and new decals on the way from discontinueddecals.com.  New propeller (I acquired with a seized 1967 johnson 9.5 from craigslist for $60) installed.  Just need to work out a bug with the kill switch.

Scrapping a 1964 Evinrude 9.5

Another Craigslist purchase for $60.  Had a seized motor, plastic junk propeller, and looked like a wreck.  What it did have was a good front motor mount, and other parts I can use to keep the others running and start a parts inventory.  The motor became unstuck just as I was finishing the teardown.  Go figure.

Rebuilding the 1968 Evinrude

Finished the rebuild (for now) of the 68 Evinrude.  Rebuilt the carburetor with a BRP rebuild kit.  Solved her idling problem, but she was hardly pumping any water, and water was pouring out from under the shroud.  Also, gear oil leaking out of the exhaust.  Did some research and with help from chrysleroutboarddude on Youtube, new and used parts, and some OMC marine special tools, I rebuilt the lower unit completely.  Discovered that the "mechanic" the previous owner had used did some interesting repairs.  The water pump housing was from a 6 hp model, bored out with no seal on the top end, and the impeller was toast.  Lots of crud in the water tube and thermostat as well.  I tore the whole thing down.  The front weep hole on the lower unit case was completely solid with crud, and I had to drill it out.  Amazing that water didn't collect there and break it by freezing, Next, I sandblasted and repainted the case, propeller, and skeg.  All new shift shaft seals, clutch dog, impeller, impeller housing, wear plate, upper and prop shaft seals.  Thermostat was cleaned, tested, and whole water system cleaned.  New gasket made and thermostat reinstalled.  Front motor mount is broken, but this will be replaced this winter.  Tested successfully in a barrel, then taken up north to the clean waters of gods land, where she performed well after fine tuning the idling of her rebuilt carburator.  Turned out to be a nice motor.  More to come on that front motor mount...