Saildrive Drain Screw Problem

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   The drain screw on my saildrive was repaired at some point with some epoxy and a helicoil that has given up, leaving a messy, oversized drain hole.  The mechanic is recommending replacing the lower saildrive housing.  There was also water in with the gear oil, possibly leaking around the shaft seal or I'm thinking more likely around the drain screw.  Haven't been able to get the prop off yet to look at the shaft seal because the set screws are stuck.  Next is to try to take off the prop without removing the blades.
Would it be possible/a good solution to drill out the drain screw and tap it for a larger size plug?  Epoxy and some sort of insert allowing for the standard size screw?  Other ideas?  Anyone have a spare lower housing piece?

Thanks!

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Vance Newell Members Profile Send Private Message Find Members Posts Add to Buddy List Crew Joined: 23 April 2015 Status: Offline Points: 27	Post Options Post Reply Quote Vance Newell Report Post Thanks(0) Quote Reply Topic: Saildrive Drain Screw Problem Posted: 09 August 2015 at 11:01am
	The drain screw on my saildrive was repaired at some point with some epoxy and a helicoil that has given up, leaving a messy, oversized drain hole. The mechanic is recommending replacing the lower saildrive housing. There was also water in with the gear oil, possibly leaking around the shaft seal or I'm thinking more likely around the drain screw. Haven't been able to get the prop off yet to look at the shaft seal because the set screws are stuck. Next is to try to take off the prop without removing the blades. Would it be possible/a good solution to drill out the drain screw and tap it for a larger size plug? Epoxy and some sort of insert allowing for the standard size screw? Other ideas? Anyone have a spare lower housing piece? Thanks!

Mike V Members Profile Send Private Message Find Members Posts Add to Buddy List Skipper Joined: 19 August 2012 Location: Hamilton On Status: Offline Points: 64	Post Options Post Reply Quote Mike V Report Post Thanks(0) Quote Reply Posted: 11 August 2015 at 6:55am
	Check out timesert.com. They make a stainless insert that could probably repair your sail drive. It is a threaded plug insert, unlike heli coils that are just the tread portion. Edited by Mike V - 11 August 2015 at 6:57am
	Sparkplug Hull #182 NYC

Vance Newell Members Profile Send Private Message Find Members Posts Add to Buddy List Crew Joined: 23 April 2015 Status: Offline Points: 27	Post Options Post Reply Quote Vance Newell Report Post Thanks(0) Quote Reply Posted: 11 August 2015 at 1:08pm
	Thanks Mike! We are going to repair the drain hole with epoxy this time and see how the rest of the drive holds up. The zinc mounting holes had also been repaired, but the shaft seal looks good/recently replaced. Hopefully it all holds together for at least a few years. I may be in the market for a replacement leg in the future. The timesert seems like a much more substantial option than a helicoil. Vance

frfletch Members Profile Send Private Message Find Members Posts Add to Buddy List Commodore Joined: 13 May 2008 Location: Canada Status: Offline Points: 365	Post Options Post Reply Quote frfletch Report Post Thanks(0) Quote Reply Posted: 14 August 2015 at 7:46pm
	The oil plug screw is not a difficult fix. Many ways to do it. First, there is a lot of meat back there on that area of the leg. I think the original plug is a 5mm screw. It is easy to drill and tap it with something a bit larger, such as a 1/4" x 28 tpi, and obviously change he screw to suit. An epoxy such as J-Weld would work as well for the oil plug, providing that you can get the hole clean enough to fill. Likely oil will want to keep dripping out of there which won't make it easy. Again it is a matter of filling, drilling, then tapping with 5mm. You can't use J-Weld on the zinc mounting holes, however, because you need the screws to have conductivity with the metal of the leg. The easiest thing to do with that is to fill the old holes with epoxy and abandon them, then rotate the hole pattern and drill and tap new holes to mount the zinc. Regarding the removal of your prop, you do not need to loosen the allen screws to get the prop off. Just take out the cotter pin, take off the nut with your fingers, and remove the prop.

bal149 Members Profile Send Private Message Find Members Posts Add to Buddy List Skipper Joined: 14 August 2010 Location: canada Status: Offline Points: 67	Post Options Post Reply Quote bal149 Report Post Thanks(0) Quote Reply Posted: 18 August 2015 at 9:34am
	to stop oil from dripping in the drain hole, I would suggest you shove a piece of bread in there. If you can't get it out once you have finished there is no real problem as the oil will break it up once the drive is engaged. Then flush . Plumbers do this when soldering copper pipes to keep water away

Vance Newell Members Profile Send Private Message Find Members Posts Add to Buddy List Crew Joined: 23 April 2015 Status: Offline Points: 27	Post Options Post Reply Quote Vance Newell Report Post Thanks(0) Quote Reply Posted: 26 August 2015 at 11:11am
	Rotating the zinc is a great idea! I will do it next time she is out of the water - they were able to use the existing holes this time. They were also able to get the drain hole clean enough to epoxy, so that is done. Going to leave it with no drain until next service to eliminate that as a possible source of the water leaking in. Great ideas! Thank you for your suggestions! Hoping to finally be in the water by this weekend.