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INSTRUCTIONS
Note: Grease EVERYTHING that has any metal to metal contact!!!! This includes the prop to shaft joint, prop coupler to engine coupler, shaft to coupler joint, etc. and ALL threads. Replace all plated bolts, washers, etc. with stainless if you can. The most critical and difficult procedure in this project is aligning the engine. The engine must be aligned in three different planes. The alignment relative to the waterline (horizontal) will be accomplished with a bubble level, protractor and adjustable square. The side to side alignment (yaw) will be accomplished when the engine is on centerline and the stern tube is glassed in. The vertical alignment will be accomplished by equalizing the engine mount heights. Before you pull the boat, determine your boat's water level by measuring down the cockpit drain hose and marking that level on the hose with tape. Pull the boat. It is an easier installation if you take the time to level the boat at this time. Not necessary, but remember what Ms. Stewart says, Use colored water in 1/2" clear plastic hose fore and aft and athwartships to easily level your boat. Remove the rudder. It is held on with one, two or three 1/4" bronze screws located on the underside of the pintles. Use a car jack (slowly!) if you're having problems pushing the rudder up. Move the rudder back and forth to overcome friction. Don't force it! Locate the stern tube support area on the hull in the propeller aperture. Decide at this point what size stern tube you wish to use.
Drilling the Hole for the Shaft Log in the Keel
NOTE: This operation is critical to the success of the project. It is recommended that you consult with a marine professional before undertaking this part of the project.
If you use the 1-5/8" you may have a problem finding a 1-5/8" shaft seal. I believe I used a 1-1/2" stern tube. Locate the center of the stern tube support in the prop aperture and drill a 1/4" hole. You will be drilling through about 1/2" to 1" of fiberglass. Using the 1/4" hole as a guide, drill a hole sized for your stern tube. Install the engine mounts onto the engine. Adjust them to their middle positions for now. Ensure the proper mounts are installed to either the front or the rear of the engine. Although they look similar, they are not interchangeable. #70 go on the front and #50 go on the rear. Hoist the engine up using a come-along on the boom end or whatever system you can devise. Lower the engine through the companionway opening. This is easier than lowering it through the access hatch. The dry engine weight is approx. 160 lb..
YAW ALIGNMENT
First, we will align the engine in the "yaw" direction. Open the engine compartment access hatch. Slide the engine aft along the engine bed until it is approx. centered fore and aft and all the mounts are properly supported. If you want to make use of the engine decompression lever for hand starting (which, by the way, has never been successfully achieved) make sure you can operate the lever in its full up position. If it hits the underside of the cockpit, lower the mounts. If it still hits, bend the lever 90 degrees (this is what I had to do). There should be at least 3/8" clearance from any part of the engine and the bed (use a 3/8" wooden dowel or bolt). Remember, when this single cylinder engine is idling it will be moving all over the place and if you do not have the proper clearance the engine will be banging against the side of the bed. You will have to redo the hole locations or grind fiberglass (this is a Screw Top Tale!). Insert the stern tube through the hole you drilled. Leave about two inches of the stern tube sticking out of into the aperture. You may have to relieve the hole a little with a file to allow the stern tube to fit through. It is O.K. if the hole becomes irregular because you're going to fiberglass the entire area anyway. Insert one of the shaft bearings into the aft end of the stern tube. Insert one of the shaft bearings into the forward end of the stern tube. Rub soapy water liberally inside the bearings. This will allow the prop shaft to slide easily along the bearings. Insert the prop shaft through the bearings and into the prop coupler. Fasten the prop coupler to engine coupler. Locate the centerline of the boat above the front of the
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