Stubborn Flywheel, Gale 40 hp

[Buccaneer]

bobw wrote:

I used the Freeze-Off on a seized transom clamp screw on my ’56 30hp Johnson. Heated the transom bracket up with the torch real good then sprayed the clamp screw with the Freeze-off. The quick temperature change shrunk the clamp screw and it backed right out. Thought it might work on your flywheel but sounds like yours might need dynamite!

Next time I get to the big city I’ll look for a can of Freeze off……. or could I just put the whole
powerhead in the freezer a couple of days (leaving the puller on, under tension) and
quick heat the flywheel with the torch?????

Prepare to be boarded!

[bobw]

Hadn’t thought of that but guess it could work.

Bob

1937 Champion D2C Deluxe Lite Twin
1954 Johnson CD-11
1957 Evinrude Fastwin 18
1958 Johnson QD-19
1958 Johnson FD-12
1959 Johnson QD-20

“Every 20 minute job is only a broken bolt away from a 3-day project.”
"Every time you remove a broken or seized bolt an angel gets his wings."

[fleetwin]

Finding a used flywheel should be relatively easy….I would consider using the air hammer around the flywheel, close to the taper, while an assistant prys up on the flywheel. Just be careful and don’t get hurt….

[Buccaneer]

fleetwin wrote:

Finding a used flywheel should be relatively easy….I would consider using the air hammer around the flywheel, close to the taper, while an assistant prys up on the flywheel. Just be careful and don’t get hurt….

At one time I tried “ringing” the flywheel with a blunt bit in the air hammer,
hoping the sonic vibrations would help the puller “do it’s thing”, but
the only thing it did was ring my ears.

Prepare to be boarded!

[bobw]

Buc,
Any luck yet??

Bob

1937 Champion D2C Deluxe Lite Twin
1954 Johnson CD-11
1957 Evinrude Fastwin 18
1958 Johnson QD-19
1958 Johnson FD-12
1959 Johnson QD-20

“Every 20 minute job is only a broken bolt away from a 3-day project.”
"Every time you remove a broken or seized bolt an angel gets his wings."

[Buccaneer]

bobw wrote:

Buc,

Any luck yet??

Bob, the power head is sitting on my workbench with the flywheel puller on,
under pressure, while I’m trying to build a 10′ x 10′ “outboard” shed. My
wife thinks rakes, shovels, ladders, weed wackers, etc., are going in it.
I glance occasionally at the bench to see if the flywheel magically popped off, but always “No”.
Sadly, my Cadillac boat project is in the garage with the transom boards tore apart,
awaiting it’s turn.

Prepare to be boarded!

• This reply was modified 4 years, 7 months ago by Buccaneer.
• This reply was modified 4 years, 7 months ago by Buccaneer.

[bobw]

So much to do, so little time!!

Bob

1937 Champion D2C Deluxe Lite Twin
1954 Johnson CD-11
1957 Evinrude Fastwin 18
1958 Johnson QD-19
1958 Johnson FD-12
1959 Johnson QD-20

“Every 20 minute job is only a broken bolt away from a 3-day project.”
"Every time you remove a broken or seized bolt an angel gets his wings."

[Buccaneer]

So, I put the 40 hp Gale power head with the stuck flywheel in the freezer
for two days with the flywheel puller attached and tensioned, ready for
action. I had the torch ready to go in the garage. Rushed said power head
out to the garage, fired up the torch…… nothing happened. Tightened
the puller up more….. same old story, snapped off one of the 1/4″
shoulder bolts. Decided to drill out the three 1/4″ holes for 5/16″ shoulder
bolts, which I had purchased, “just in case”. Drilled out the first hole
with my “F” drill bit. Started tapping with my USA made tap. Had 1/16″ to
go tapping the first hole, and yes, I snapped off the tap.
Made several futile attempts removing the tap, including welding a nut on.
Gave up, and decided to destroy the flywheel to end this long tiresome
saga. Drilled holes all around the crankshaft in the same arc as the three
puller bolt holes. Spend much time connecting the dots, a.k.a. “Holes”
with punches, chisels, and more drilling at angles. The broken tap fought
to the end hole the flywheel on, but I finally managed to break the flywheel
free. Was then stuck with the steel hub over the crankshaft. Attached
my bearing puller to it and it wouldn’t budge…… not that I really expected it
to. Then put the air grinder and cut off wheel to work, cutting thru the hub
where the flywheel key was, so the keep the grinding wheel away from the
crankshaft taper. The hub did not want to budge until I cut a slot on the other
side and got the torch out and started “heating”…… after two months of
monkeying around with this flywheel, I was finally satisfied with a mighty “POP”.
I was afraid of ruining some good coils, but alas, I need not have worried
about that…… they were originals.
I’m only going to finish this project “if” I find a cheap flywheel.
I would love to hear the old Gale run, but it being a “non electric start” model,
not sure I’d be able to pull start it anyway!

Prepare to be boarded!

[Buccaneer]

Good used hub for sale, lol.

Prepare to be boarded!

[bobw]

Man, that was one tough mother – those 100ft-lb flywheels must do their job well! Hate to see the flywheel destroyed to get it off, but at least it’s off. I was hoping your idea of the freezer and torch method would have worked.

Bob

1937 Champion D2C Deluxe Lite Twin
1954 Johnson CD-11
1957 Evinrude Fastwin 18
1958 Johnson QD-19
1958 Johnson FD-12
1959 Johnson QD-20

“Every 20 minute job is only a broken bolt away from a 3-day project.”
"Every time you remove a broken or seized bolt an angel gets his wings."

[Author]

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